Porsche 996 TT Repair Manual Download Page 1969

Page: 1969 / 2099

Removing differential and differential lock

1. Remove transmission. ’ 34 35 27 Removing and refitting the transmission −

GT2.

2. Fasten the transmission on assembly support.

3. Pull out hexagon−head bolts (no. 1 in overview) and halfshaft flange (no. 2 in

overview).

4. Unscrew hexagon−head bolts (no. 3 in overview) and disassemble cover for final drive (no. 4 in

overview), possibly with a rubber hammer.

5. Remove

differential.

top of page

Installing diffential and differential lock

1. Insert

differential.

2. Insert cover with new, lightly oiled O−ring (no. 5 in overview) and screw in hexagon head bolts.

Tightening torque: 25 Nm (18.5 ftlb.)

3. Push in halfshaft flange and screw in hexagon−head bolts.

Tightening torque: 44 Nm (32,5 ftlb.)

4. Refitting transmission. ’ 34 35 27 Removing and refitting the transmission −

GT2.

top of page

Tightening torques

Location

Thread

Tightening torque Nm (ftlb.)

Halfshaft flange fastening screws

M 8

44 (32,5 ftlb.)

Cover fastening screws

M 6

25 (18.5 ftlb.)

996840, 996841

einordnung

Removing differential and differential lock

1906

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1967
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Summary of Contents for 996 TT

Page 1: ...einordnung...

Page 2: ...Spare wheel 11 Wheel alignment 11 Dimensions 12 Weights according to DIN 700 20 12 Filling capacities 13 Performance data 14 Climbing performance 15 Specific power 15 0 Entire vehicle General 16 Lift...

Page 3: ...s 37 Activating systems 37 Read out fault memory 37 Load Navigation 38 01 Battery checking the charge state 39 Tools 39 Checking charge state with battery tester 39 01 Windscreen wiper washer system h...

Page 4: ...56 Electrical system 56 Exhaust system 56 Emission control 56 Technical data 57 Engine 58 Engine design 58 Engine cooling 59 Engine lubrication 59 Engine control 59 Fuel system 60 Electrical system 6...

Page 5: ...osition 89 Checking clutch free play 89 Checking the pedal end position pedal return return force 89 03 Changing transmission oil 90 Changing transmission oil 90 Tightening torques 90 03 Checking and...

Page 6: ...emblies 112 Running gear adjustment wheel alignment values 112 Storage of assemblies and running gear 112 03 Tyres and spare wheel checking condition and tyre pressure 113 Checking condition 113 Tyre...

Page 7: ...lights 130 Adjusting the main headlights 130 Setting 131 Adjusting the main headlights USA version 132 Fog light adjustment 132 Removing main headlight 132 Installing main headlight 133 03 Windscreen...

Page 8: ...n tightening torques 147 Front wheel drive Z 96 00 147 Front axle drive tightening torques 148 3 Technical data 149 5 speed Tiptronic transmission A 96 50 150 149 Tightening torques for Tiptronic tran...

Page 9: ...172 Imprinting new vehicle identification number 172 Materials tools 173 5 Change identification data plate 174 5 Undersealing 176 Overview diagram lower front of vehicle 176 Overview diagram bottom...

Page 10: ...st overvoltage 189 Replacing control modules 189 5 Tools and metalworking tools for body repairs 190 Straightening systems 190 Metalworking tools 190 Electrical equipment 190 Mechanical equipment 191...

Page 11: ...ystem of the rear spoiler 221 6 General information on installing and removing car windows 222 Removing glass with cutting wire separator 222 Cutting power when removing glass with cutting thread 229...

Page 12: ...40 Tightening torques for front axle 251 Cross member side member 1 component 251 Diagonal brace 251 Control arm 251 Spring strut wheel carrier 252 Front axle final drive drive shaft Turbo 252 Stabil...

Page 13: ...271 Adjusting toe 272 Toe difference angle 274 44 Wheel rims and tires 275 Tire condition tire pressure 275 Tire pressure of cold tires approx 20 C 275 911 Turbo 275 911 GT2 M002 M003 275 Overview of...

Page 14: ...possibility 294 Adjusting switch if pedal travel is too large 294 46 Tightening torques for mechanical brake 295 46 Technical data Brake wear limit Turbo 296 Technical data Turbo with cast iron brake...

Page 15: ...as a function of ambient temperature 316 91 Retrofitting mobile communication systems 318 96 Additional alarm system M 536 320 Removing alarm siren and tilt sensor 320 97 Measurement of closed circui...

Page 16: ...nstructions for collapsible wheel spare wheel Turbo with PCCB 353 Mounting collapsible spare wheel Turbo with PCCB 353 Placing collapsible spare wheel in to the vehicle Turbo with PCCB 354 45 60 Steer...

Page 17: ...70 Connectors 370 Removing and installing optical contacts 371 Removing optical contacts on plug side 372 Installing optical contacts on plug side 373 Removing optical contacts on bushing side 374 Ins...

Page 18: ...ssing ring knurled screw in 436 Assembling crankshaft 436 13 73 37 Disassembling and assembling belt tensioner 440 Assembly note 442 13 78 19 Removing and installing drive belt engine installed 443 Re...

Page 19: ...oil pressure sender 499 Removal 499 Installation 500 17 07 19 Removing and installing oil temperature sensor 502 Removal 502 Installation 503 17 28 19 Removing and installing check valve engine instal...

Page 20: ...60 55 Replacing fuel filter 563 Removing fuel filter 563 20 66 01 Checking quantity delivered by fuel pump 568 20 68 19 Removing and installing fuel cooler 571 Removing fuel cooler 571 Installing fuel...

Page 21: ...emoval 609 Installation 609 24 00 33 Completing the vacuum connections 610 24 25 19 Removing and installing air cleaner 613 Removing air cleaner 613 Installing air cleaner 615 24 42 19 Removing and in...

Page 22: ...generator 646 Removing bracket for generator 646 Removal 646 Installing bracket for generator 649 27 60 19 Removing and installing starter manual transmission 652 Removing the starter 652 Installing...

Page 23: ...45 19 Removing and installing release bearing clutch removed 679 Removing release bearing 680 Installing release bearing 680 30 50 19 Removing and installing clutch 682 Tools 682 Removing clutch 682...

Page 24: ...ole 711 Removing shift console 712 Installing shift console 713 Tightening torques 714 34 12 19 Removing and installing shift and selector cables 715 Tools 715 Removing and installing shift and select...

Page 25: ...738 Tightening torques 739 37 15 19 Removing and installing selector lever cable 740 Tools 740 Removing and installing selector lever cable 740 Removing selector support 740 Installing selector suppor...

Page 26: ...ing rear wheel bearing 769 Tools 769 Removing and installing rear wheel bearing 769 Notes on removal and installation 770 Removal 771 Installation 772 42 71 19 Removing and installing rear spring stru...

Page 27: ...rview 802 Installation 803 45 64 19 Remove and install booster pump for PSM 807 Removal 807 Installation 808 46 11 15 Adjusting the brake pushrod 809 46 36 20 Removing and installing the front disc br...

Page 28: ...d 832 47 15 19 Removing and installing brake master cylinder 834 Removal 834 Installation 835 47 70 19 Removing and installing brake booster 837 Removal 837 Installation 839 48 10 19 Removing and inst...

Page 29: ...ing rear lid 887 Disassembling rear lid 887 Assembling rear lid 890 Replacing the model logo 893 55 91 19 Removing and installing lid hinge 894 57 11 37 Disassembling and assembling door handle 897 57...

Page 30: ...front spoiler 936 Assembling front spoiler 937 Installing front spoiler 939 63 50 19 Removing and installing rear bumper 941 Removing rear bumper 941 Installing rear bumper 943 Additional assembly in...

Page 31: ...earview mirror 983 Removing the rearview mirror 983 Installing the rearview mirror 985 68 17 37 Disassembling and assembling centre console 987 Disassembling and assembling cover for the oddments tray...

Page 32: ...the instrument panel 1021 Disassembling the instrument panel 1021 Removing the regulator for wiping interval 1026 Removing the cigarette lighter 1026 Assembling the instrument panel 1027 Installing th...

Page 33: ...emoving heating air conditioning control 1062 Performing system test 1062 Tests 1063 87 03 17 Assembly work on the air conditioning system 1064 Service unit SECU 134 1064 Assembly work involving the r...

Page 34: ...emoving and installing footwell blower outlet sensor 1085 Removing footwell blower outlet sensor 1085 Installing footwell blower outlet sensor 1085 87 59 19 Removing and installing outside temperature...

Page 35: ...7 Installing navigation unit 1097 Device code input 1097 91 13 19 Removing and installing GPS antenna 1099 Removing GPS antenna 1099 Installing GPS antenna 1099 91 20 19 Removing and installing the ca...

Page 36: ...stalling tank for windscreen washer system 1117 92 67 19 Removing and installing fluid level indicator 1118 Removing fluid level indicator 1118 Installing fluid level indicator 1118 92 70 19 Removing...

Page 37: ...moving and installing the hazard warning light switch 1135 Removing hazard warning light switch 1135 Installing hazard warning light switch 1135 94 53 19 Removing and installing bulb for side directio...

Page 38: ...ulb for door warning light 1148 Installing bulb for door warning light 1148 96 22 19 Removing and installing bulb for interior light 1149 Removing bulb for interior light 1149 Installing bulb for inte...

Page 39: ...d installing injection valves Engine removed 1183 Removing injection valves of cylinder bank 1 3 1183 Removing injection valves of cylinder bank 4 6 1184 Installing injection valves of cylinder bank 1...

Page 40: ...ng gear housing 1220 Removing input and output shaft 1221 Overview 1221 Removing shafts 1222 Dismantling input shaft 1223 Overview 1223 Disassembling shaft 1225 34 35 37 Assembling transmission 1226 T...

Page 41: ...19 Removing and installing sealing ring for halfshaft flange 1254 Tools 1254 Removing sealing ring for halfshaft flange 1254 Installing sealing ring for halfshaft flange 1255 Tightening torques 1255...

Page 42: ...60 01 Checking function of installed viscous clutch 1272 Test conditions 1272 Checking function of installed viscous clutch 1272 39 60 01 Checking function of installed viscous clutch 1275 Test condi...

Page 43: ...rive 1297 Installing the front wheel drive 1298 Tightening torques 1299 39 90 55 Replacing and checking transmission oil in final drive 1300 Tools 1300 Changing transmission oil in final drive 1300 Ti...

Page 44: ...cs for edge damage 1337 Note concerning bores perforations in the brake disc friction surface 1338 Note on bedding in the new brake pads 1338 46 53 02 Checking rear gray cast iron brake discs wear ass...

Page 45: ...l housings and side members 1369 Materials and tools 1370 50 79 55 Replacing front inner side member 1372 Removing front inner side member 1372 Preparing and fitting the front inner side member for in...

Page 46: ...53 05 55 Replacing rear closing panel 1419 Cutting out rear closing panel 1419 Preparing the rear closing panel for installation and fitting 1421 Welding in rear closing panel 1422 Tools and materials...

Page 47: ...sides 1467 Adjustment procedure 1468 Checking the adjustment 1468 Adjusting the lower stop of the power window unit 1468 64 12 19 Removing and installing windscreen 1470 Removing windscreen 1470 Prep...

Page 48: ...dow of Cabriolet 1501 Removing rear glass window of Cabriolet 1501 Installing rear glass window of Cabriolet 1503 Tools and materials 1505 Use of the circlip pliers 1505 64 86 19 Removing and installi...

Page 49: ...546 Installing inner sill 1548 68 05 19 Removing and installing inner sill passenger s side 1550 Removing inner sill 1550 Installing inner sill 1551 68 11 19 Removing and installing glove compartment...

Page 50: ...moving rear three point belt 1589 Installing rear three point belt 1591 69 13 19 Removing and installing belt tensioner as of MY 2002 1593 Removing belt tensioner 1593 Installing belt tensioner 1594 6...

Page 51: ...s 1627 Removing and installing trim of A B and C pillars 1627 Installing trim of A B and C pillars 1629 70 57 19 Removing and installing A pillar trim Cabriolet 1631 Removing A pillar trim 1631 Instal...

Page 52: ...g electric motor for seat adjustment 1674 Tools 1675 Test plan for the seat adjustment 1675 72 88 19 Removing and installing electric motor for the front seat height adjustment 1677 Removing electric...

Page 53: ...91 10 19 Removing and installing display and operator control unit PCM 1711 Removing display and operator control unit PCM 1712 Installing display and operator control unit PCM 1712 Connecting and sw...

Page 54: ...alling antenna amplifier as of MY 2003 1747 Removing antenna amplifier 1748 Installing antenna amplifier 1748 91 86 19 Removing and installing control module for antenna 1749 Removing control module f...

Page 55: ...air Groups 1780 Legend for structure of sequence description 1780 Structure of exploded view 1782 Structure of sequence description 1783 97 Wiring diagram for 911 Turbo 996 01 model 1785 97 Wiring dia...

Page 56: ...cking paint finish 1810 01 Completing vehicle and checking equipment for completeness 1811 Checking vehicle equipment for completeness 1811 Tools 1811 Completing the vehicle 1812 3 Technical Data GT2...

Page 57: ...Wear limit technical Data GT2 1836 40 Disassembling and assembling front spring strut GT2 1837 Notes about adjustment work on the spring struts 1837 Disassembling and assembling front spring strut GT...

Page 58: ...s 1864 Overview 1865 Disassembly and assembly instructions 1867 Disassembly 1867 Assembly 1867 Tightening torques 1868 34 52 37 Disassembling and assembling gear housing GT2 1869 Tools 1869 Overview 1...

Page 59: ...1888 Tools 1888 Removing sealing ring for drive shaft 1888 Installing sealing ring for drive shaft 1889 Tightening torques 1890 39 08 15 Adjusting drive set GT2 1892 Tools 1892 Sequence of adjustment...

Page 60: ...0 Removing and installing the rear disc brake pads GT2 Turbo with PCCB 1919 Removal 1920 Installation 1921 Bedding in the brake pads 1922 46 50 19 Removing and installing the front PCCB brake disc 192...

Page 61: ...using 1948 Tightening torques 1948 Assembling front gear set 1948 Assembling gear set 1948 Tightening torques 1950 Fitting front transmission case cover 1951 Fitting cover 1951 Tightening torques 1951...

Page 62: ...2001 1993 Removing bucket seat GT2 1993 Installing bucket seat GT2 1995 Fitting six point seat belt GT2 1996 96 61 19 Removing and installing relay for main switch GT2 as of MY 2001 1998 Installing th...

Page 63: ...cover 2024 Removing and installing wiring harness 2024 Replacing the model logo 2025 Test and adjustment values 2025 Tightening torques 2026 Materials and tools 2026 55 91 19 Removing and installing...

Page 64: ...recorded with the 911 Turbo in one file and is separated with a cardboard cover sheet This supplement should be filed behind the 911 Turbo material in the file Group 3 Transmission manual transmissio...

Page 65: ...ystem Electrical system Exhaust system Emission control Transmission Clutch Transmission Body designs Running gear Brakes Wheels and tyres Spare wheel Wheel alignment Dimensions Weights according to D...

Page 66: ...pe M96 70 No of cylinders 6 Bore 100 3 94 mm in Stroke 76 4 3 01 mm in Cubic capacity 3600 219 7 cm3 cu in Compression ratio 9 4 1 Max engine power as per 80 1269 EEC 309 420 kW HP Net power as per SA...

Page 67: ...divided crankcase made from cast light alloy separate cylinder housing Cylinder housing Cast light alloy with wet light alloy bushings inserted Nikasil coating Crankshaft Forged supported by 8 bearing...

Page 68: ...cooling Water cooling 3 radiators ahead of the front wheels Additional radiator for Tiptronic vehicles Two electric fans controlled in three stages top of page Engine lubrication Engine lubrication Ty...

Page 69: ...d loop controlled on air side top of page Fuel system Fuel system Injection ME 7 8 Digitale Motor Electronic engine control module ECM Injection valves controlled sequentially Fuel supply 1 electrical...

Page 70: ...a 2 stage catalytic converter on left right secondary air system OBD II ORVR top of page Transmission Transmission Engine and transmission bolted together to form a power unit Rear axle drive via dou...

Page 71: ...ar 1 12 1 00 5th gear 0 92 0 83 6th gear 0 75 Reverse gear 2 86 1 93 3 16 Final drive Bevel gear wheel Final drive ration rear axle i front axle 3 44 2 889 2 883 3 44 Transmission weight dry kg lbs 68...

Page 72: ...turns 4 05 Stabilizer diameter 23 6 x 3 5 mm in tube type stabilizer Vibration damper Double acting hydraulic twin tube gas filled vibration damper Rear axle Multi link axle Wheel suspension Wheels i...

Page 73: ...in Brake discs front 330 13 00 rear 330 13 00 mm in Effective brake disc front 134 5 28 rear 136 5 36 mm in Brake disc thickness front 34 1 34 rear 28 1 10 mm in Effective total brake pad area per whe...

Page 74: ...can also be mounted optionally rear max 210 km h or front max 240 km h Snow chains approved if special chains are used top of page Spare wheel Spare wheel Collapsible wheel 165 70 R16 92P Vredestein...

Page 75: ...Width 1830 72 0 mm in Height 1295 51 02 at DIN empty weight mm in Wheel base 2350 92 59 mm in Track widths 18 inch mm in front 1465 57 72 mm in rear 1522 59 97 mm in Ground clearance 90 3 55 mm in for...

Page 76: ...awbar load none none Permissible roof load kg lbs with Original Porsche Roof Transport System 75 165 75 165 top of page Filling capacities Note Measurement of the engine oil level by instrument or oil...

Page 77: ...ll volume nominal volume Approx 63 13 65 l Imp gal Coolant 28 6 07 l Imp gal 29 6 28 l Imp gal Brake fluid reservoir Approx 0 63 0 136 l Imp gal Tank for windscreen washer and headlight cleaning syste...

Page 78: ...ear 89 5 70 4 3rd gear 50 9 38 1 4th gear 37 4 24 3 5th gear 29 0 17 9 6th gear 21 9 top of page Specific power Specific power Manual transmission Tiptronic 4 98 5 12 kg kW 3 66 3 77 kg HP 3 71 3 81 k...

Page 79: ...points shown in the figure Make sure the screw connections for the diagonal braces are accessible When driving onto a platform lift make sure that there is sufficient distance between the platform lif...

Page 80: ...Power unit Engine M96 70 Engine Engine design Engine cooling Engine lubrication Engine control top of page Engine M96 70 top of page Power unit 17...

Page 81: ...ngine speed limitation by fuel cutoff at 6750 rpm Idle speed 740 40 rpm Automatic transmission 740 40 rpm Engine weight as per DIN 70020 A kg Manual transmission 260 572 7 Automatic transmission 253 5...

Page 82: ...Valve clearance Hydraulic valve clearance compensation Valve timing with 1 mm valve travel and zero clearance kinetic clearance of the operating plunger taken into account basic inlet camshaft setting...

Page 83: ...DME individual spark coils knock control Firing order 1 6 2 4 3 5 Ignition timing control Via DME ECM Spark plugs Bosch FR 5 LOC Beru 14 FR 5 LDU Electrode gap mm in 1 6 0 2 0 06 0 008 E gas Electroni...

Page 84: ...996 2001 General data Manual transmission G 96 50 Transmission ratios Z1 Z2 Z2 Z1 1st gear 11 42 3 82 2nd gear 21 43 2 05 3rd gear 27 38 1 41 4th gear 34 38 1 12 5th gear 37 34 0 92 6th gear 40 30 0...

Page 85: ...rbo 996 world wide 2001 General data Front axle final drive Z 96 00 Transmission ratio final drive Z2 Z1 i 31 9 3 44 Final drive Bevel gear drive without hypoid offset Filling capacity approx 1 5 l 99...

Page 86: ...ent arrangement Airbag System B05 top of page Body of high strength steel 1 The indicated body parts are made by welding together plates of differing thicknesses and characteristics and then deep draw...

Page 87: ...work Body repairs by means of reshaping are not possible if these body parts are correspondingly deformed Here the repair must be carried out using new parts or by means of sectional repairs The indi...

Page 88: ...ainage Rear of sliding roof 2 Water drainage Front of sliding roof 3 Water drainage Evaporator of heating and air conditioning system 4 Water drainage Tank tray 5 Water drainage Radiator tank top of p...

Page 89: ...Refrigerant circuit 1 Compressor 2 Condenser 3 Fluid tank 4 Expansion valve 5 Evaporator top of page Component arrangement Airbag System B05 einordnung Refrigerant circuit 26...

Page 90: ...ht 4 Driver s airbag unit 5 Side airbag 6 Contact unit 7 Side airbag sensor 8 Belt buckle driver passenger 9 Plug connection child restraint system 996420 996421 996450 996451 996620 996621 996650 996...

Page 91: ...oad Amperage rating Row A 1 High beam headlight right 15 2 High beam headlight left 15 3 Side lights right 7 5 4 Side lights left 7 5 5 Number plate light instrument lighting 15 6 Seat heating 25 7 Fo...

Page 92: ...1 DME relay 25 2 Ignition relay oxygen sensors 30 3 Control module for central locking system alarm system power windows 15 4 Fuel pump relay 25 5 Engine compartment fan optional 5 6 Windshield wipers...

Page 93: ...r seat memory 7 5 3 Control module memory for seat adjustment left 30 4 Control module memory for seat adjustment right 30 5 Information system 7 5 6 Terminal 30 telephone navigation control module 7...

Page 94: ...ry with engine running Never start engine without securely connected battery Do not use a boost charger to start the engine Whenever possible use jump leads with overvoltage protection Always disconne...

Page 95: ...fore the engine control module can relearn the idle speed and mixture adaptation values Problem Remedy After disconnection of the power supply the idle speed might change or fluctuate briefly until th...

Page 96: ...ablishes smooth shifting top of page 6452 Power windows Problem Remedy The limit positions of the power windows are deleted from the control module when the battery is disconnected and connected Manua...

Page 97: ...ivated If the power supply is restored with the fuel level at less than 19 l it is possible that the fuel level display may subsequently display too much This may lead to the vehicle breaking down Ref...

Page 98: ...DME control module under Vehicle data 2 This code is also available from the Porsche IPAS 3 Switch on the PCM with a free panoramic view for approx 20 minutes to load GPS almanac 4 The date and time a...

Page 99: ...ar checking operation Parking assistant Selecting reverse gear and checking operation Activating the automatic cruise control during the test drive and checking operation Checking operation of heating...

Page 100: ...using the cursor keys 3 Change to Sports car analysis and start After analysis was carried out print out analysis log and assign to vehicle procedure 4 Select vehicle type Change to Sports car hand o...

Page 101: ...When PCM is installed continue with Load Navigation After the test drive the fault memory must be read out again or erased If the same faults are still present proceed in accordance with 0 20 97 Diag...

Page 102: ...ehicle battery and check the charge state according to the operating instructions for the tester Evaluation of test results and further procedures Open circuit voltage Charge state Evaluation and proc...

Page 103: ...avoid scratches do not rub with dry or only damp cloths paper towels or insect removal sponges Note The headlight washer nozzles are pre set It is not necessary to adjust them Check the function fluid...

Page 104: ...s sets the hours When this set up button is pressed the minute display blinks Now the minutes can be set by turning to the left right Compare the time in the instrument cluster with time in PCM if pre...

Page 105: ...the ignition must be switched off and on after the adjustment has been made with the lights switched on 5 After this the adjustment must be checked again top of page Adjusting the main headlights 1 Op...

Page 106: ...orrespond to the stipulated values using a headlight adjustment unit A Lateral adjustment B Height and lateral adjustment C Fog light adjustment top of page Adjusting the main headlights USA version N...

Page 107: ...or 75 kg the tyre pressure must correspond to the stipulated values using a headlight adjustment unit C Fog light adjustment Note Switched on headlights must not be covered by a front apron or film 9...

Page 108: ...and fans to high and low and check the air vents for air throughput Check operation of front seats Check operation of radio Check operation of door mirror check adjustment options Check operation of...

Page 109: ...cover for the glove compartment and the cover for the centre console Open and close these items again in turn 2 As soon as the vehicle is locked the LED in the middle of the dashboard should show a do...

Page 110: ...After a time delay which can be set the door mirror is lowered by the set value as soon as reverse gear is engaged If reverse gear is disengaged again or the mirror adjustment switch touched with rev...

Page 111: ...tion off then switch the ignition on 2 Switch on the PST2 and wait for the start up screen 3 Press the key to go to the next level 4 Select the vehicle type 911 996 Turbo in the left hand window using...

Page 112: ...F8 coding Note The selected door mirror is now activated top of page Adjusting the lowering angle for the passenger door mirror Note The lowering angle of the passenger door mirror can be adjusted wi...

Page 113: ...ect the Seat memory control module and press the key to go to the next level 7 With the v key select Modify coding and press the key to go to the next level 8 With the v key select the menu item Parki...

Page 114: ...are installed when commencing journey If the spring strut locking devices are not removed this will seriously impair the handling behaviour and thus the driving safety The spring strut locking device...

Page 115: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Removing spring strut locking devices 52...

Page 116: ...Technical Data GT2 Engine Engine design Engine cooling Engine lubrication Engine control Fuel system Electrical system Exhaust system Emission control top of page Technical Data GT2 53...

Page 117: ...se made from cast light alloy separate cylinder housing Cylinder housing Cast light alloy with wet light alloy bushings inserted Nikasil coating Crankshaft Forged supported by 8 bearings Crankshaft be...

Page 118: ...changer on pressure side behind oil pump Oil pressure at n 5000 rpm T 90 C Approx 6 5 bar Oil pressure indicator Oil pressure indicator lamp plus instrument Oil consumption Approx 1 0 l 1000 km top of...

Page 119: ...tput 1680 W top of page Exhaust system Exhaust system 2 pipe 3 way catalytic converter exhaust system rear mufflers top of page Emission control Europe RoW Stereo oxygen sensor closed loop control and...

Page 120: ...Technical data Engine Engine design Engine cooling Engine lubrication Engine control Fuel system Electrical system Exhaust system Emission control top of page Technical data 57...

Page 121: ...e from cast light alloy separate cylinder housing Cylinder housing Cast light alloy with wet light alloy bushings inserted Nikasil coating Crankshaft Forged supported by 8 bearings Crankshaft bearings...

Page 122: ...changer on pressure side behind oil pump Oil pressure at n 5000 rpm T 90 C Approx 6 5 bar Oil pressure indicator Oil pressure indicator lamp plus instrument Oil consumption Approx 1 0 l 1000 km top of...

Page 123: ...output 1680 W top of page Exhaust system Exhaust system 2 pipe 3 way catalytic converter exhaust system rear mufflers top of page Emission control EURO II Stereo oxygen sensor closed loop control and...

Page 124: ...are fuel resistant Wear a breathing mask with activated carbon filter do not breathe in any fuel fumes Ensure that there is adequate ventilation or extract all fuel fumes Before opening the fuel line...

Page 125: ...socket The diagnosis socket is located inside the vehicle below the instrument panel near the driver left hand drive vehicles or the passenger right hand drive vehicles Arrow 1 Start Porsche System T...

Page 126: ...ating steering checking operation Shifting gear checking operation Parking assistant Selecting reverse gear and checking operation Activating the automatic cruise control during the test drive and che...

Page 127: ...on overview of the drive belt engine installed To check the drive belt it must be removed and installed Procecedure is described below top of page Removal overview of the drive belt engine installed 1...

Page 128: ...st be replaced at 60 000 miles for USA vehicles and at 80 000 km or 48 000 miles for RoW vehicles according to the maintenance plan top of page Installation overview of the drive belt engine installed...

Page 129: ...p wheel 3 Tensioning the drive belt 4 Tightening the fastening screws on servo pump 5 Installing the air cleaner assembly 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Installatio...

Page 130: ...unter clockwise and remove from the headlight housing 3 Take defective bulb out of the bulb socket bayonet lock top of page Installing bulb for direction indicator light 1 Install new bulb and ensure...

Page 131: ...se and drain off the engine oil 2 Undo the oil drain plug on the oil container and drain off the oil An open ended wrench must be used to counter it in order to avoid damage to the oil container 3 Dra...

Page 132: ...he oil filter element To do this pull the oil filter element out and replace the filter element and the two O rings 1 Oil filter cover 2 O ring 71 5 x 3 5 3 O ring 10 x 2 4 Oil filter element 5 Oil fi...

Page 133: ...k 7 Tighten oil filter To do this use the special tool release key 9204 and tighten the oil filter cover to 25 Nm 19 ftlb Slowly pour 7 8 litres of engine oil into the oil container Note Fill in engin...

Page 134: ...m ftlb Oil drain plug on crankcase M20 x 1 5 70 52 Oil drain plug for oil container M20 x 1 5 60 44 Oil drain plug for turbocharger M18 x 1 5 30 22 Oil filter cover 25 19 996420 996421 996450 996451 9...

Page 135: ...ug in order to prevent damage to the oil container Then equip the oil drain plug with a new sealing ring and tighten to a torque of 60 Nm 44 ftlb 3 Drain engine oil from the turbochargers To do this u...

Page 136: ...ment Vehicle horizontal Engine at operating temperature Engine idling Vehicle stationary WARNING The engine oil level must not exceed the seventh segment on the instrument cluster display Note The oil...

Page 137: ...in the figure When driving onto a platform lift ensure that there is sufficient distance between the platform lift and the vehicle Item Special tool designation Remarks A Spark plug socket wrench S 97...

Page 138: ...olts for this purpose 6 Undo hexagon socket head bolts arrows of the ignition coils 7 Pull off the ignition coils and hang them to the side with connected cables 8 Unscrew spark plugs with commerciall...

Page 139: ...ls and tighten the screws to 10 Nm 7 5 ftlb 6 Reinstall the heat shields above the exhaust system 7 Reinstall charge air cooler 8 Fit rear spoiler 63 55 19 Removing and installing rear spoiler 9 Lower...

Page 140: ...heck the antifreeze content with a frost protection testing device If it is lower than 35 C it should be corrected accordingly 2 Checking the cooling system for leaks connect the cooling system test d...

Page 141: ...Workshop Equipment Manual Chapter 2 4 No 160 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Coolant checking level antifreeze content and leaks 78...

Page 142: ...t film mass air flow sensor Push the plug downwards and press the grooved surface at the sides Pull the plug up and off at the same time 2 Pull off the connecting hose between the left turbocharger an...

Page 143: ...he rear of the air cleaner housing 5 Tilt air cleaner housing outwards Tilt the housing upwards and to the right by 90 and then turn the housing to the left by approx 90 6 Unclip the hot film mass air...

Page 144: ...the screws arrows and pull the two housing halves apart 8 Take out the cleaner element c Take out the air cleaner element d Wipe out the two housing halves with a cloth top of page Installing air cle...

Page 145: ...air cleaner housing b Retighten the two air cleaner housing halves with the screws arrow 2 Clip in hot film mass air flow sensor cable Insert the cable into the omega clip on the left air cleaner hous...

Page 146: ...y approx 90 and push the rubber hose over the flange d Swivel the housing downwards by 90 4 Tighten the fastening screw M6 x 34 Tightening torque 10 Nm 7 5 ftlb 5 Tighten the hose clamp on the connect...

Page 147: ...ch the connecting hose between the left turbocharger and the intake distributor Note The hose must engage audibly 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Installing air clea...

Page 148: ...the retaining clips immediately 3 Unscrew the fastening screw M6 x 34 at the rear of the air cleaner housing 4 Undo hose clamp Undo the hose clamp arrow between the air cleaner housing and the intake...

Page 149: ...the plug connection and collect the residual fuel Protect open lines against dirt 10 Remove fuel filter with holder To to this bend the retaining clip upward as shown arrow and simultaneously remove...

Page 150: ...el filter with holder on the coolant expansion tank again and press it down at rear The holder must engage audibly 14 Connect plug connector of the fuel supply line The connector must engage audibly P...

Page 151: ...right by approx 90 and push the rubber hose over the flange Then swivel downwards by 90 19 Tighten the fastening screw M6x34 to 10 Nm 7 5 ftlb 20 Tighten the hose clamp on the connecting hose Reconne...

Page 152: ...by pulling at the pedal without the use of force towards the driver s seat Note The pedal must not give way during the process If it gives way the fault is in the boost spring or in the pedals The cl...

Page 153: ...screw and drain plug and drain the oil with the vehicle horizontal 3 Clean the drain plug and filler plug 4 Replace sealing ring for drain plug and tighten to 30 Nm 22 ftlb 5 Fill with oil up to the b...

Page 154: ...ng up the ATF Tightening torques top of page Tools Item Special tool designation Remarks Connection hose 9507 1 top of page Checking and topping up the ATF Note Top up only with ATF approved by Porsch...

Page 155: ...and engine idling The air conditioning system and the heater must be switched off The vehicle must stand horizontally 1 Place oil collection pan under the transmission 2 Connect the Porsche System Tes...

Page 156: ...w special tool 9507 1 A onto the charging valve and top up ATF via the charging valve until excess ATF emerges at the control bore 8 Replace sealing ring for cap nut 9 Screw on cap nut for charging va...

Page 157: ...ial tool designation Remarks Connection hose 9507 1 top of page Replacing ATF fluid Note Top up only with ATF approved by Porsche See Parts Catalogue Filling capacity approx 9 0 litres Change quantity...

Page 158: ...do and tighten the cap nut for the charging valve counter with an open ended wrench 5 Screw off cap nut for the charging valve 6 Screw connection hose 9507 1 A onto charging valve Top up with ATF via...

Page 159: ...the start of the test 11 Check the ATF level again and top up if necessary Checking and topping up the ATF 12 Replace sealing ring for cap nut and screw cap nut onto the charging valve Tightening tor...

Page 160: ...ter Installing ATF filter Tightening torques top of page Tools Item Special tool designation Remarks Connection hose 9507 1 top of page Removing ATF filter 1 Remove underbody panels rear and centre 2...

Page 161: ...inly coat gasket on the suction collar of the new ATF filter with Vaseline and install filter 2 Clean ATF pan 3 Fit ATF pan with new seal Tighten the screws crosswise in several stages Tightening torq...

Page 162: ...on Thread Tightening torque Nm ftlb Drain plug to ATF pan M 10 22 16 ATF pan to transmission M6 8 6 Transmission cross member to body M 10 65 48 996420 996421 996450 996451 996620 996621 996650 996651...

Page 163: ...Tightening torques top of page Tools Item Special tool designation Remarks Filling system V A G 1924 top of page Changing transmission oil in final drive Note Use only oils approved by Porsche See Pa...

Page 164: ...ible on the vehicle 5 Fill in oil with special tool V A G 1924 up to the lower edge of the oil filler opening 6 To check the oil level insert a suitable object such as a bent wire into the filler open...

Page 165: ...ing torques Location Thread Tightening torque Nm ftlb Oil drain plug M21 x 1 5 25 19 Oil filler plug M18 x 1 5 22 16 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tightening torqu...

Page 166: ...nderbody cover front 2 Unscrew oil filler plug A 3 Unscrew the oil drain plug B and drain the oil with the vehicle horizontal 4 Clean the drain plug and filler plug 5 Fill with oil up to the bottom ed...

Page 167: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tightening torques 104...

Page 168: ...2 1 Remove rear centre and left underbody trim 2 Unscrew oil filler plug 1 3 Unscrew oil drain plug 2 and let oil drain off into a suitable container top of page Topping up transmission oil GT2 1 Clea...

Page 169: ...Tightening torques Location Thread Tightening torque Nm ftlb Oil filler plug M22 x 1 5 30 22 Oil drain plug M22 x 1 5 30 22 996840 996841 einordnung Tightening torques 106...

Page 170: ...in Before filling the reservoir any existing leaks must be eliminated on the suction side Alternatively the defective part on the pressure side should be replaced For the Turbo not only the power ste...

Page 171: ...rises In this case the engine must be run for approx 20 seconds immediately prior to the fluid level check If coolant hoses come into contact with Pentosin thoroughly clean them with water IMMEDIATELY...

Page 172: ...influences for example by stone damage or during assembly work The steering gear can become leaky if dirt or moisture enter a leaky bellows Visually inspect the bellows for damage 996420 996421 996450...

Page 173: ...ecking the play and dust bellows 1 Check play 2 Visually inspect the dust bellows for damage Note When doing so the rubber dust bellows should be pressed down with the fingers in order to reveal hidde...

Page 174: ...ouch The procedure for the front axle is as follows Turn the front wheels as far as they will go Perform a visual inspection of the visible surfaces on the left and on the right After turning the fron...

Page 175: ...eel alignment values Check that the screw connections of the running gear adjustment facility wheel alignment values at the front and rear are secure top of page Storage of assemblies and running gear...

Page 176: ...cient tread depth foreign bodies pricks cracks and bulges in the sidewall ply breakage The air pressure must never be lower than the values specified these are minimum pressures A visual inspection of...

Page 177: ...sent Spare wheel collapsible wheel not available However there is a tyre repair kit in the luggage compartment which can be used to repair the damaged tyre in the event of damage For repairs in the ev...

Page 178: ...66 container volume 30 litres 000 043 203 67 The information applies to vehicles with PSM Turbo and without PSM GT2 top of page Changing the brake fluid Note Observe brake fluid quality Use only new D...

Page 179: ...and to determine the brake fluid used 4 Continue brake fluid change at the brake calipers no special sequence 5 Open every bleeder valve until clear bubble free brake fluid emerges and until the corr...

Page 180: ...effect Adjusting the parking brake 1 Remove the rear wheels 2 Undo the parking brake lever and push back the disc brake pads of the rear axle until the brake disc can rotate freely Note To make the t...

Page 181: ...st the adjustment nut of the turnbuckle until both wheels can be turned manually with difficulty 8 Release the parking brake lever and check whether both wheels can be turned freely 996420 996421 9964...

Page 182: ...vehicle if braking effect is impaired The brake pads must be replaced when the brake pad warning indicator lights up but no later than when there is a residual pad thickness of 2 mm Note If brake pad...

Page 183: ...wear wear limit 2 mm 3 Carry out visual inspection of the brake discs for wear 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Brake system visual inspection of the b...

Page 184: ...f 130 Nm 96 ftlb Never use an impact bolter Do not loosen the wheel bolts to check the tightness Tighten the wheel bolts or check for tightness tightening torque 130 Nm 96 ftlb 1 Tighten the wheel bol...

Page 185: ...lled Checking the catch bar Check the catch bar for wear When the wear limit is reached the catch bar must be replaced Dimension for new part Wear limit 7 mm 4 mm top of page Checking safety hook fron...

Page 186: ...e Checking inner release of luggage compartment Trunk Entrapment DANGER Danger of accident If a person trapped in the front luggage compartment unlocks the front lid when the vehicle is in motion the...

Page 187: ...Fastening screws of lower part of the lid lock on front closing panel M6 10 7 5 Nm ftlb Fastening screws on door lock on the doors M8 20 2 15 1 5 Nm ftlb Fastening screws of latch striker on side sec...

Page 188: ...of the seat belt must engage audibly in the buckle An abrupt pull on the belt strap must lock the belt retractor top of page Condition inspection The belt strap must undergo a visual inspection for da...

Page 189: ...light 1 Function test of airbag warning light in instrument cluster a Switch on ignition Note The airbag warning light must light up for approx 3 seconds If the warning light does not light up check t...

Page 190: ...iagram Fault present after approx 30 seconds Airbag warning light Insert E1 fuse again Clear fault memory Read out fault memory again after approx 30 seconds No fault stored 996420 996421 996450 99645...

Page 191: ...test on the roll over protection system only with the hardtop and covering cap removed and the convertible top open 1 Connect the Porsche System Tester to the diagnostic socket data link connector on...

Page 192: ...oosen the antenna at the two top fastening screws and unscrew the two bottom fastening screws Remove antenna part 3 Remove the particle filter upwards out of the housing guide arrow top of page Instal...

Page 193: ...the headlight adjustment screws 4 Clean the cover lens and switch on the dipped beam headlights Note The vehicle must be on a horizontal surface Make the adjustment with the regulator switch set to 0...

Page 194: ...d side with the dotted 15 line of the adjustment unit Next perform the horizontal adjustment of the dipped beam headlights 2 To do this line up the left horizontal section of the light dark limit when...

Page 195: ...t with the vehicle ready for driving fuel tank full driver s seat occupied by a person or 75 kg the tyre pressure must correspond to the stipulated values using a headlight adjustment unit C Fog light...

Page 196: ...t horizontally to the rear 5 Turn the socket wrench through approx 180 arrow A and leave it in position 6 The headlight is now unlocked and can be pulled forwards out of the wing 7 Turn the socket wre...

Page 197: ...ear arrow C In the process the headlight lock must engage with an audible and perceptible click 3 Check the correct seating of the headlight e g by pulling gently in the area of the fog light 4 Insert...

Page 198: ...ight lenses Never use chemical cleaning agents To avoid scratches do not rub with dry or only damp cloths paper towels or insect removal sponges Note The headlight washer nozzles are pre set It is not...

Page 199: ...and fans to high and low and check the air vents for air throughput Check operation of front seats Check operation of radio Check operation of door mirror check adjustment options Check operation of o...

Page 200: ...eimported from the USA must be maintained according to the maintenance schedules for RoW vehicles The maintenance schedules for the US market have been added to the Technical Manual for the sake of co...

Page 201: ...fluid use only original Porsche brake fluid Checking and changing the brake fluid Condition report preparing long life guarantee Form WKD 444 010 02 German Form WKD 444 020 02 English Form WKD 444 02...

Page 202: ...in the control module top of page Additional maintenance replacing spark plugs Additional maintenance replacing spark plugs Replacing spark plugs OK 911 Turbo GT2 every 40 000 km 24 000 mls top of pa...

Page 203: ...checking roll over protection system Condition report preparing long life guarantee Form WKD 444 010 02 German Form WKD 444 020 02 English Form WKD 444 021 02 US English Form WKD 444 030 02 French For...

Page 204: ...eimported from the USA must be maintained according to the maintenance schedules for RoW vehicles The maintenance schedules for the US market have been added to the Technical Manual for the sake of co...

Page 205: ...Checking and changing the brake fluid Check roll over protection system only 911 Turbo Cabrio Passenger protection maintenance colon checking roll over protection system Condition report preparing lon...

Page 206: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Maintenance after 4 8 10 then every 2 years 143...

Page 207: ...in the control module top of page Additional maintenance replacing spark plugs Additional maintenance replacing spark plugs Replacing spark plugs OK 911 Turbo GT2 every 40 000 km 24 000 mls top of pa...

Page 208: ...t preparing long life guarantee Form WKD 444 010 02 German Form WKD 444 020 02 English Form WKD 444 021 02 US English Form WKD 444 030 02 French Form WKD 444 031 02 French Canadian Form WKD 444 040 02...

Page 209: ...996 2001 General data Manual transmission G 96 50 Transmission ratios Z1 Z2 Z2 Z1 1st gear 11 42 3 82 2nd gear 21 43 2 05 3rd gear 27 38 1 41 4th gear 34 38 1 12 5th gear 37 34 0 92 6th gear 40 30 0...

Page 210: ...smission M8 x 20 23 17 Bracket for clutch control shaft on transmission M6 x 16 10 7 5 Guide tube for release bearing on transmission housing M6x14 10 7 5 Drive shaft on transmission flange M10 45 33...

Page 211: ...rive shaft on final drive M8 39 29 Rear transmission support to transmission mount M10 x 90 65 48 Rear transmission support on body M10 65 48 Front transmission support on front axle cross member M10...

Page 212: ...the converter components from excessive centrifugal forces with the vehicle stationary this car has been equipped with torque converter centrifugal force protection This protection ensures that the e...

Page 213: ...5 29 21 Drain plug for rear axle oil M24 x 1 5 25 19 Hydraulic control unit on transmission housing M6 8 6 Short flanged shaft to differential M10 x 55 46 34 Cover for final drive on transmission hous...

Page 214: ...tening torques Location Thread Tightening torque Nm ftlb Screw plug oil drainage and oil filling M18 28 21 Cover to final drive M8 25 19 Long neck tube to final drive M8 25 19 Drive shaft to final dri...

Page 215: ...and front axle cross member M12 100 74 Tank strap to body M8 x 40 23 17 Pipe holder to transmission support M6 7 5 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Front axle drive...

Page 216: ...t lip 0 Entire vehicle General 01 Fitting front lip GT2 WARNING Danger of injury and damage to property if spring strut locking devices are installed when commencing journey If the spring strut lockin...

Page 217: ...locking devices from all spring struts To do this pull spring strut locking devices off the springs 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Removing spring str...

Page 218: ...nts shown in the figure Make sure the screw connections for the diagonal braces are accessible When driving onto a platform lift make sure that there is sufficient distance between the platform lift a...

Page 219: ...s If no all wheel drive test stand roller type test stand is available the following limit values must not be exceeded for conventional roller type test stands Test speed max 7 5 km h Test duration ma...

Page 220: ...in the rocker switch are lit When braking the vehicle is also stabilised when the PSM is switched off One sided wheel spin is also prevented when the PSM is switched off On Tiptronic vehicles the fun...

Page 221: ...ases the driving stability on slippery roads When PSM is switched off the slip monitoring slip upshift function is also switched off In this way the Tiptronic enables an active sporty driving style al...

Page 222: ...f rear end Side of rear end CAUTION Danger of material damage corrosion due to entry of water when removing plugs The body apertures are sealed with plugs in the factory and must be sealed with the pl...

Page 223: ...Bottom of front end F Plug hole 20 mm top of page Side of front end A Rubber grommet hole 20 mm B Rubber grommet hole 30 mm top of page einordnung Bottom of front end 160...

Page 224: ...loor A Rubber grommet hole 20 mm C Plug hole 10 mm D Plug hole 10 mm E Plug hole 15 mm top of page Top of lower side member and floor A Rubber grommet hole 20 mm K Plug hole 30 mm einordnung Bottom of...

Page 225: ...top of page Bottom of rear end A Rubber grommet hole 20 mm D Plug hole 10 mm E Plug hole 15 mm F Plug hole 20 mm top of page Top of rear end einordnung Top of lower side member and floor 162...

Page 226: ...ole 20 mm B Rubber grommet hole 30 mm L Plug hole 55 mm top of page Side of rear end A Rubber grommet hole 20 mm D Plug hole 10 mm 996420 996421 996450 996451 996430 996431 996840 996841 einordnung To...

Page 227: ...spare part range in the case of repair work accessories must be sealed before assembly painting according to the following illustrations The sealing material 000 043 204 38 can be applied directly to...

Page 228: ...midity Higher air humidity or dampening with water accelerates the hardening process The hardening can be checked with a nail test Press a finger nail gently into the hardened sealing mass if this cau...

Page 229: ...Sliding roof panel 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Sliding roof panel 166...

Page 230: ...e Pre paint new parts from the inside Reshape damaged areas Reshaped damaged area by straightening so that adjacent contours or gap dimensions correspond to the series condition Roughly cut out damage...

Page 231: ...Paint the repaired area If necessary touch up the undersealing Seal cavities Fit accessories 996420 996421 996450 996451 996430 996431 996840 996841 einordnung 5 Work sequence for accident repair 168...

Page 232: ...ping forces can be expected Repair work is often only possible in this case by replacing the body parts In general an impact occurs diagonally or offset to the vehicle axle so that mixed forms are usu...

Page 233: ...to a lifting platform and raise Measure the measuring points or reference points specified in the repair check dimensions table diagonally horizontally and vertically using a compass or an electronic...

Page 234: ...Paint build up Paint Manual Build up paint on bright sheetmetal panels according to the painting methods described in the Paint manual Repair or create standard undersealing by applying long life und...

Page 235: ...sed through with a X so that it remains legible The vehicle identification number to be newly imprinted should be imprinted above the crossed through identification number top of page Imprinting new v...

Page 236: ...ea with clear lacquer 1 Cathodic dip coating is the primer applied to the sheetmetal parts at the factory top of page Materials tools Item Designation of the special tool Remarks 1 Number embossing to...

Page 237: ...When ordering the indentification data plate the item number 1 and vehicle identification number 2 must be specified 1 Installation location of identification data plate on the vehicle A Right side s...

Page 238: ...5 Identification data plate Canada a Item number b Vehicle identification number 996420 996421 996450 996451 996840 996841 996430 996431 einordnung 5 Change identification data plate 175...

Page 239: ...d materials Note In the case of repairs before painting or the installation of ancillaries the standard stone shield undersealing of the body structure must be must be recreated as shown in the follow...

Page 240: ...4 mm to 0 6 mm C 1 mm to 1 3 mm top of page Overview diagram bottom of lower side member and floor A 0 6 mm to 0 8 mm B 0 4 mm to 0 6 mm C 1 mm to 1 3 mm top of page einordnung Overview diagram lower...

Page 241: ...alant 9320 Sprayable seam and compartment sealant Manufacturer Henkel Teroson GmbH Postfach 10 56 20 69046 Heidelberg www teroson com 2 Recommendation Multi press telescopic spray gun For working with...

Page 242: ...tube 4 Water drainage Water channel side section 5 Water drainage Evaporator for heating and air conditioning system 6 Water drainage Tank tray 7 Water drainage Radiator tank 8 Water drainage Inner pa...

Page 243: ...5 Check dimensions for body repair Cabriolet structure Structure dimensions for cabriolet top of page Structure dimensions for cabriolet 5 Check dimensions for body repair Cabriolet structure 180...

Page 244: ...e measuring points are identified for the right or left side in relation to the direction of travel viewed from above Dimensions which are only specified for the left side of the vehicle also apply to...

Page 245: ...section Screwed point thread M8 P5L Convertible top support inner rear side section Screwed point thread M8 P5R Convertible top support inner rear side section Screwed point thread M8 P6R Auxiliary f...

Page 246: ...of the mounting plates by raising the vehicle slightly and conducting a visual inspection In order to guarantee that the vehicle is not lifted off the mounting plates during assembly work the vehicle...

Page 247: ...smoke gases with a suitable extraction system refer to Workshop Equipment Manual Wear suitable protective equipment such as protective clothing gloves a welding shield and if necessary a protective m...

Page 248: ...lled air conditioning systems a very strong overpressure may be caused in the system which may lead to an explosion No welding soldering or hot air heating may take place on parts of the filled air co...

Page 249: ...em and alignment bench work within the framework of body repair Safety instructions for door CAUTION Danger of material damage if the door lock is installed incorrectly Malfunctions in the alarm syste...

Page 250: ...tion plan body CAUTION Danger of corrosion and of uncontrolled water penetration when removing plugs The body apertures are sealed with plugs in the factory and must be sealed with the plugs provided...

Page 251: ...int Manual Build up paint on bright sheetmetal panels according to the painting methods described in the Paint manual Repair or create standard undersealing by applying long life undersealing material...

Page 252: ...the welding point on the part to be welded Do not touch electronic control units or electric cables with the ground connection or the welding electrode Replacing control modules The replacement of ele...

Page 253: ...king tools Note Detailed and additional information about tools and equipment can be found in the Workshop Equipment manual top of page Straightening systems Shown on Celette type top of page Metalwor...

Page 254: ...Drill 1 Angle grinder large 2 Angle grinder small 3 Sander 4 Hot air gun 5 Mechanical equipment 6 Hole punch 7 Edge setter Compressed air equipment einordnung Electrical equipment 191...

Page 255: ...9 Air chisel 10 Body saw 11 Spotweld cutter Welding equipment 12 Multispot spot welder 13 MIG welder 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Compressed air equipment 192...

Page 256: ...as welding top of page Resistance spot welding A Spot seam single row B Spot seam double row C Spot seam double row offset top of page Inert gas arc welding MAG procedure A Plug weld B Stitch weld C F...

Page 257: ...A Hard soldering 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Gas welding 194...

Page 258: ...page Floorpan check dimensions Note All dimensions are measured to the middle of the hole or screwed point The dimensions are measured directly and therefore are oblique dimensions Dimensions in brack...

Page 259: ...Rear axle rear 792 2 P18 P18 P18 Rational location hole side member rear 945 1 P19 P19 P19 Engine mount location hole outside 889 2 P20 P20 P20 Engine mount 780 2 P21 P21 P21 Impact absorber pipe rear...

Page 260: ...d point thread M10 P11 Transmission support rear screwed point thread M 12 x 1 5 P12 Hoist car jack rear location hole P13 Diagonal brace front screwed point thread M10 P14 RA front screwed point thre...

Page 261: ...icle 1 Water drainage Rear of sliding roof 2 Water drainage Front of sliding roof 3 Water drainage Evaporator of heating and air conditioning system 4 Water drainage Tank tray 5 Water drainage Radiato...

Page 262: ...rance in the openings that is too great or too small the movable body parts or the accessories must be centred accordingly Ensure that the gaps do not run in a wedge shaped fashion or do not narrow at...

Page 263: ...C 4 5 mm Modular headlight to wing D 3 5 0 8 mm E 2 1 5 mm Wing to front trim F 3 0 5 mm Gap is evident Front wing to outer side section G 4 1 0 5 mm H 1 2 mm Wing to front cover J 4 0 5 mm Windscree...

Page 264: ...imension Note Door to front wing A 4 2 5 mm Door only lowered max 1 mm Door to outer side section B 4 1 0 5 mm C 1 5 mm Doors only lowered D 3 5 1 0 5 mm E 2 mm Doors only lowered F 4 1 0 5 mm Doors o...

Page 265: ...ear side window J 7 1 mm Side section to outer roof panel K 25 3 1 mm Roof joint strip to outer roof panel L 3 2 1 mm Sliding roof panel to outer roof panel M 5 5 0 5 mm All the way round sliding roof...

Page 266: ...0 5 mm Gap is evident Tail light to outer side section D 3 0 5 mm E 2 1 mm Tail light only lowered Rear trim to tail light F 5 2 mm G 2 1 2 mm Tail light only lowered Rear lid to rear trim H 5 2 mm J...

Page 267: ...ter side section O 4 5 1 mm Rear centre panel to rear lid P 6 1 2 mm Rear lid only lowered max 1 mm Rear window to outer roof panel Q 7 3 1 2 mm Rear window to rear centre panel R 8 5 1 2 mm S 8 9 mm...

Page 268: ...Tail light only lowered Rear trim to tail light F 5 1 1 mm M 2 1 2 Tail light only lowered Rear lid to side section G 4 5 1 mm Determine gap left to right Rear lid to rear spoiler H 5 2 mm Rear lid on...

Page 269: ...2 mm Rear window to outer side section N 6 mm O 7 mm Determine left to right Outer side part to rear centre part P 4 3 1 mm Q 1 2 mm Adhesive seam Rear centre part to rear lid R 5 2 1 Only lowered top...

Page 270: ...flap to side trim panel D 4 2 5 1 mm Rear side section flap raised max 0 5 mm lowered max 1 5 mm E 4 2 mm Rear side section flap raised max 1 mm Rear side section flap to frame trim panel for roll ove...

Page 271: ...part to convertible top compartment lid A 5 1 0 5 mm Continuous seam joining line B to C 5 1 0 5 mm Convertible top compartment lid to rear lid D 6 4 1 0 5 mm Convertible top compartment lid to rear...

Page 272: ...t to convertible top compartment lid A 5 1 0 5 mm Continuous seam joining line B to C 5 1 0 5 mm Convertible top compartment lid to rear lid D 6 4 1 0 5 mm Convertible top compartment lid to spoiler t...

Page 273: ...owered Rear window to rear roof frame Hardtop C 10 4 mm D 3 1 5 mm Hardtop to convertible top compartment lid E 5 5 2 mm Hardtop to convertible top compartment lid F 6 5 2 mm G 7 8 4 mm Tail light onl...

Page 274: ...996420 996421 996450 996451 996630 996631 996430 996431 996620 996621 996650 996651 einordnung Diagram Gap dimensions hardtop 211...

Page 275: ...ing work Reshaping Separation points Diagram Body model year 2002 The following body parts are made of high strength steel HS 1 Bearer side at spare wheel well left and right 2 Connection bracket inne...

Page 276: ...t C Reinforcement cross member firewall inner right Note Body parts 18 and 22 are welded together from plates of different material thicknesses and characteristics and are then deep drawn Body parts A...

Page 277: ...l Porsche parts must be used for repair work top of page Tailored blanks The indicated body parts are made by welding together plates of differing thicknesses and characteristics and then deep drawing...

Page 278: ...ly Original Porsche parts or sections of Original Porsche parts may be used The body and floor assembly are produced in series from deep drawn panels For this reason accident damage must be reshaped i...

Page 279: ...used for repair work The separation of damaged body parts should not take place until after reshaping against the accident direction has taken place and connection pieces have been straightened Body...

Page 280: ...structural body parts have been used in the body for passive safety As of model year 2002 all vehicles will be constructed with the structural parts shown in the following diagram Structural body part...

Page 281: ...ide member 4 Inner side part 5 Sliding roof reinforcement frame 6 Seat well cross tube 7 Gusset plate and reinforcement plate of belt height adjuster 8 Roof frame reinforcement pipe 996420 996421 9964...

Page 282: ...isconnected in order to ensure that the cutter cannot be switched on accidentally Material damage when removing the glass from car windows CAUTION Danger of paint damage and damage to surrounding sect...

Page 283: ...riod of 1 minute Safety instructions for sliding roof CAUTION Damage to water drainage channel and sliding roof mechanism when sliding roof panel is removed The rear water drainage channel or the slid...

Page 284: ...tem is under approx 30 bar pressure when extended Do not smoke during work avoid open flames Danger of fire Do not swallow hydraulic oil avoid contact with skin eyes Rinse with water in the event of c...

Page 285: ...o specific vehicles can be obtained from the instructions in the corresponding chapters in the Technical Manual Item Designation Source Remarks A Glass separating tool VAG 1474 B See Workshop Equipmen...

Page 286: ...may cause cut injuries due to the knife of the cutter Always wear protective gloves when working on car windows Wear protective goggles when cutting out car windows Only replace the cutting knife wit...

Page 287: ...ification number C is completely covered by the protective film when pushing through the adhesive bead b Push through adhesive bead on the glass on the edge of the vehicle identification number C with...

Page 288: ...pull the cutting thread through 5 Attaching cutting thread to the body h Attach the loose end of the cutting thread B firmly at a suitable point on the body with the fastening screw 2 of a component e...

Page 289: ...take onto the glass by moving the actuating lever 8 Separating glass as far as P1 o Separate glass by spooling the cutting thread on the spooling device as far as point P1 9 Repositioning spooling dev...

Page 290: ...rce can be increased by moistening the fastening intake 11 Separating glass as far as P3 y Release spooling device z Position deflection roller in the upper right corner aa Press deflection roller wit...

Page 291: ...n deflection roller in the upper left corner aj Press deflection roller with fastening intake firmly against the glass ak Fix fastening intake onto the glass by moving the actuating lever al Pass cutt...

Page 292: ...ooling device as far as point P5 Note The fastening force can be increased by moistening the fastening intake 15 Removing glass 16 Pulling off surrounding section at Carefully detach the surrounding s...

Page 293: ...equired Average cutting power Favourable angle average traction required Low cutting power Optimum angle minimum traction required 996420 996421 996450 996451 996840 996841 996430 996431 einordnung Cu...

Page 294: ...lour code Model year 01 02 03 04 05 06 07 08 09 10 Biarritz white 9A2 1 X 9A3 1 X Carrara white B9A 1 2 X X X Black 741 1 X 747 2 X Black 041 1 2 X X X Guards red 84A 1 X X X X 80K 2 X X X X Speed yel...

Page 295: ...X Atlas grey metallic M7X 1 2 X Midnight blue metallic 39C 1 X X 37W 2 X X Lagoon green metallic M6W 1 2 X X 1 Water based 2 Conventional top of page Special colours Colour designation Colour code Mod...

Page 296: ...etallic 23F 1 X X X X 22D 2 X X X X Midnight blue metallic 39C 1 X X 37W 2 X X Zanzibar red pearl effect 1A8 1 X 1A9 2 X 1 Water based 2 Conventional 996420 996421 996450 996451 996840 996841 996430 9...

Page 297: ...ombined procedure handling double cartridge press top of page Overview of tools and materials Item Designation Source Remarks A Double cartridge gun VAS 5237 See Workshop Equipment Manual Chapter 3 5...

Page 298: ...aces Note The table below shows how to use cleaners primers and activators when preparing the adhesive surface Preparing the body glass for installation Old glass New glass Without preliminary coat Wi...

Page 299: ...rve the safety instructions of the individual adhesive set components Note In addition to this manual observe the relevant job descriptions for installing car windows Group 64 in the Technical Manual...

Page 300: ...4 Placing mixing cartridge in the double cartridge gun d Move pressure piston back fully e Place double cartridge H5 H6 in the bonding gun A 5 Mixing adhesive components f By activating the valve arr...

Page 301: ...the car window must be assembled within this period of time In order to ensure that the substance is completely mixed apply a 30 mm long adhesive bead of fresh adhesive to a piece of cardboard before...

Page 302: ...ory tests top of page Light soiling e g dust It is possible to clean light soiling by selecting an option from the following cleaning tools and cleaning fluids Cleaning tools Cleaning fluid Cleaning p...

Page 303: ...et Note Observe cleaning instructions wipe down with clear water if necessary Solvent naphtha Note Use solvent naphtha only other solvents are not permissible 996420 996421 996450 996451 996430 996431...

Page 304: ...special category waste Compressor type 7 SB 16 Refrigerant quantity 900 g Refrigerant R 134a Refrigerant oil in the compressor 195 15 cm3 ND 8 Hexagon head bolts on Thread Tightening torque in Nm ftl...

Page 305: ...h the ignition on All loads must be switched off beforehand Never disconnect battery with engine running Never start engine without securely connected battery Do not use a boost charger to start the e...

Page 306: ...dule Note With all DME systems the engine must run for several minutes before the engine control module can relearn the idle speed and mixture adaptation values Problem Remedy After disconnection of t...

Page 307: ...nt cluster The trip counter is set to 0 when the power supply is disconnected top of page 9030 Clock Note In the case of vehicles with PCM the date and time are deleted when the battery is disconnecte...

Page 308: ...pply is disconnected the built in GPS receiver loses the so called almanac containing the satellite orbital paths The date and time are deleted when the battery is disconnected Radio stations stored b...

Page 309: ...The telephone is enabled again when the telephone PIN code is entered with the SIM telephone card inserted 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung 9110 PCM 24...

Page 310: ...rt number Quantity supplied 6 litre 000 043 203 33 Container volume 1 litre cans 6 ea Power steering and clutch actuation are supported by hydraulic auxiliary forces A tandem servo pump is available i...

Page 311: ...specifications in order to avoid overfilling and thus overflowing Multiple steering operations manoeuvring and or actuating the clutch with the engine switched off change the fluid level in the reser...

Page 312: ...r person filling in the wrong fluids at a later stage Note On right hand drive vehicles the supply tank is located in the area of the brake fluid reservoir control module for automatic headlight beam...

Page 313: ...ainer 2 does not lie between the Min and Max marking screw off the cap Counter the container when doing this Fill in Pentosin CHF 11 S hydraulic fluid up to the Max marking 3 Screw cap green 2 closed...

Page 314: ...x 1 5 160 118 Corner plate on side member M10 x 1 5 65 48 Corner plate on body M12 x 1 5 100 74 Corner plate on body with diagonal arm and side member M14 x 1 5 160 118 top of page Diagonal brace Loc...

Page 315: ...strut lock nut M52 x 1 5 50 37 Brake cover plate to wheel carrier M6 10 7 5 Brake disc on wheel hub M6 10 7 5 Brake caliper to wheel carrier M12 x 1 5 85 63 1 Speed sensor on wheel carrier M6 10 7 5 C...

Page 316: ...37 top of page Steering Location Thread Tightening torque Nm ftlb Unlisted values in Repair Group 48 Track rod ball joint pin on steering arm M12 x 1 5 75 56 Universal joint steering shaft at steerin...

Page 317: ...facing the wheel If heavily contaminated clean bolts first with a lint free cloth 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Wheel fastening 254...

Page 318: ...ier side section M6 10 7 5 Diagonal brace to body to cross member to carrier side section collar nut M10 x 1 5 M12 x 1 5 M10 x 1 5 65 48 110 81 23 17 top of page Axle strut Location Thread Tightening...

Page 319: ...uminium paste Do not grease bearing surface of the spherical cap facing the wheel If heavily contaminated clean bolts first with a lint free cloth top of page Spring strut Location Thread Tightening t...

Page 320: ...g strut lock nut M52 x 1 5 50 37 top of page Unit mount Location Thread Tightening torque Nm ftlb Engine mount to body Engine carrier to engine Engine mount to engine carrier Transmission carrier to i...

Page 321: ...00 0 517 0 533 0 550 0 567 0 583 0 600 0 617 0 633 0 650 40 0 667 0 683 0 700 0 717 0 733 0 750 0 767 0 783 0 800 0 817 50 0 833 0 850 0 867 0 883 0 900 0 917 0 933 0 950 0 967 0 983 60 1 000 Conversi...

Page 322: ...coordinates again Line to the left 40 and line upwards 1 amounts to 40 1 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Conversion from decimal degrees to minutes exa...

Page 323: ...heels mm 158 10 138 10 128 10 118 5 118 to 123 From road contact surface to lower edge of hexagon head bolt a f 18 of the tension strut screw connection to the body Rear axle height with 18 inch wheel...

Page 324: ...e case of small deviations from the toe difference angle required value as long as the value to the right and the left is almost the same Wheel alignment values Turbo USA Turbo RoW Turbo X73 20 mm low...

Page 325: ...of cold tires bar Tire wheel any damage Tires tread depth mm Incoming measurement Nominal values max Difference left right Outgoing measurement Vehicle height Front mm left right Rear mm left right Re...

Page 326: ...values into the copied alignment card Note Actual values that are identical in all versions have already been entered 3 Enter the appropriate version e g USA or RoW in the Model column 4 Carry out in...

Page 327: ...eels The quick clamping holders present can be retrofitted by replacing the clamping units on the left and right Supplier Messrs Beissbarth These converted quick clamping holders can also be used retr...

Page 328: ...etween left and right at the rear and front axles The varying strength of pads between coil springs and spring seats on the right and left spring struts on the front and rear axles is not intended for...

Page 329: ...m Tester 2 The steering angle sensor actual value must be checked after a suspension alignment which resulted in no changes being made to the wheel alignment values Note The caster is not adjustable A...

Page 330: ...g equipment and the manufacturer of the measuring platform Do not treat measured values as a whole but very critically in regard to driving dynamics high speed strength of the tyres tyre wear and cost...

Page 331: ...damage to property due to malfunctions in the PSM control range if the steering angle sensor is not calibrated or is calibrated incorrectly Calibrate steering angle sensor with wheels in straight ahe...

Page 332: ...back freely Adjusting camber WARNING Danger of injury and damage to property due to malfunctions in the PSM control range if the steering angle sensor is not calibrated or is calibrated incorrectly Ca...

Page 333: ...the Porsche System Tester 2 The steering angle sensor actual value must be checked after a suspension alignment which resulted in no changes being made to the wheel alignment values Note Use insert f...

Page 334: ...eels in straight ahead position with the Porsche System Tester 2 The steering angle sensor actual value must be checked after a suspension alignment which resulted in no changes being made to the whee...

Page 335: ...ver No 1 and the lug on the steering gear housing No 4 line up No 3 is the desired breaking point for pins in new steering gears The new pin No 2 is inserted into driver No 1 and lies with its undersi...

Page 336: ...calibrated or is calibrated incorrectly Calibrate steering angle sensor with wheels in straight ahead position with the Porsche System Tester 2 The steering angle sensor actual value must be checked...

Page 337: ...Toe difference angle The toe difference angle is not adjustable 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Toe difference angle 274...

Page 338: ...erformance this would bring about a risk of serious tire damage Besides a check on air pressure a visual check must be made for sufficient tread depth foreign bodies punctures cuts cracks and bulges i...

Page 339: ...1J x 18 ET 45 GT2 235 40 ZR 18 on 8 5J x 18 ET 40 315 30 ZR 18 on 12J x 18 ET 45 The chart of tires and wheels for summer and winter should be taken from Technical Information TI Group 4 When replacin...

Page 340: ...tubeless tyres check the sealing surface of the tyre and the disc wheel for cleanliness and any signs of damage Bear in mind here that the bead base performs the sealing function on tubeless tyres If...

Page 341: ...lateral runout of the wheel with tyre 1 25 mm Values less than 1 0 mm better around 0 5 mm are desirable After mounting the tubeless tyres inflate them without valve insert to approximately 4 0 bar g...

Page 342: ...ram selection and operating instructions of the balancing machine top of page Navigation system After a wheel change the full locating accuracy is attained only after a journey of approx 50 km if poss...

Page 343: ...r tyres If tyres are in use the kneading action activates the plasticizer in the rubber and thereby prevents hardening and cracking top of page Tyre age Note Tyres should not be older than 6 years Not...

Page 344: ...of the light alloy wheels 0 7 mm Maximum permissible radial runout and lateral runout of the wheel with tyre 1 25 mm Values less than 1 0 mm better around 0 5 mm are desirable For this purpose match t...

Page 345: ...parts in contact with the wheel and the tyres are made of plastic No large point load for wheel and tyres top of page Tools Item Designation of the special tool Explanation A Holding down device comme...

Page 346: ...damage and pressure marks on the rim flange Avoid slipping on to the rim flange Use rim flange protection assembly aid B Adhesive tape can be used to protect the rim flange in individual cases in orde...

Page 347: ...mounting lever must be kept at a safe distance from the rim This prevents damage scratches pressure marks to the rim spokes 5 Put the assembly head on the rim flange Position the assembly aid The mou...

Page 348: ...on top of the rim flange 5 Guide the tyre bead through the assembly head Fit the tyre bead in the deep bed by turning the wheel to the right 6 At the start of the mounting process of the second tyre b...

Page 349: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Fitting 286...

Page 350: ...alues less than 1 0 mm better around 0 5 mm are desirable In order to achieve low radial runout errors or to optimise smoothness of rolling it is expedient and necessary in individual cases to match t...

Page 351: ...ights than can be achieved with uncontrolled matching Fill tyres to a pressure of approx 4 0 bar At the latest when the pressure reaches 4 0 bar the beads must pop up out of the deep bed and over the...

Page 352: ...mum balancing result previously achieved by means of fine balancing finish balancers even after the wheel is re mounted Screw in wheel bolts by hand and then tighten evenly Start at the top when tight...

Page 353: ...correction table balance correction schematic and thereby eliminate the residual imbalance Further to 4b Fine balancing of the rear wheels Note Due to the all wheel drive all four wheels must be rais...

Page 354: ...d exposure to the air will reduce the bonding strength Pay attention to cleanliness Determine exact position of the balancing weights if necessary provisionally stick on the balancing weights with a s...

Page 355: ...t menu must also be performed Unintentional bending of the brake lines could lead to incorrect hydraulic allocation despite the different thread sizes used M12 x 1 and M 10 x 1 If there is a fault ind...

Page 356: ...rk on the pedals or on the brake unit the switch travel or pedal travel up to the switching point is lost The consequence The brake lights are always on or flicker when travelling over bumps In vehicl...

Page 357: ...stalling the switch for the first time it is essential to press it vertically against the bearing surface It will otherwise not be possible to lock the switch 90 turn even if great force is exerted 1...

Page 358: ...7 5 Hydraulic unit on holder M8 12 9 Booster pump for PSM on holder M6 7 5 Booster pump for PSM on body at front M6 4 3 Wheel to wheel hub M14 x 1 5 130 2 1 Replace the brake caliper fastening screws...

Page 359: ...ont and rear axles The brake calipers are painted red for visual differentiation PSM 1 Porsche Stability Management standard Brake booster vacuum 10 inch Boost ratio 3 85 Brake master cylinder front 2...

Page 360: ...ear 34 mm 28 mm Minimum brake disc thickness after machining 1 front rear 32 6 mm 1 26 6 mm 1 Brake disc wear limit front rear 32 0 mm 26 0 mm Peak to valley surface roughness of the brake disc after...

Page 361: ...connection must also be replaced Replacing the warning contact can be avoided by replacing the brake pads no later than when the pad thickness is 2 5 mm arrows Warning contacts must be replaced if th...

Page 362: ...heel removal installation During removal first remove the 3 remaining wheel bolts and remove the wheel carefully without touching the brake discs 2 Visually inspect the brake pads for wear 996420 9964...

Page 363: ...on the rear axle The brake calipers are painted yellow for visual differentiation PSM 1 Porsche Stability Management standard Brake booster vacuum 10 inch Boost ratio 3 85 Brake master cylinder front...

Page 364: ...scs minimum thickness front 33 5 mm rear 27 5 mm Thickness tolerance of the brake discs max 0 02 mm Lateral runout of the brake disc max 0 03 mm Lateral runout of the wheel hub max 0 03 mm Lateral run...

Page 365: ...ter pump for PSM Booster pump on holder Booster pump on body at front M6 M6 7 5 4 3 Brake caliper Connecting line to brake caliper Bleeder screw to brake caliper Brake pressure line to brake caliper M...

Page 366: ...bearing block top M10 x 1 5 46 34 5 Steering outer tube to pedal bearing block bottom M14 20 15 Steering lock to steering outer tube M6 13 9 8 Transverse support to steering outer tube M8 23 17 3 Tra...

Page 367: ...e side should be replaced Power steering and clutch operation are supported by hydraulic auxiliary forces The common reservoir A is located in the engine compartment Only Pentosin CHF 11 S may be fill...

Page 368: ...with Pentosin if necessary Do not add too much Pentosin In warmed up condition the fluid level must not exceed the Hot max mark top of page Bleeding the steering system 1 To fill the whole system afte...

Page 369: ...be in the designated Cold range min max level at 20 C Top up with Pentosin if necessary Do not add too much Pentosin In warmed up condition the fluid level must not exceed the Hot max mark 996420 996...

Page 370: ...vehicle if all the following conditions are met No visible damage to such front axle parts as wheel rims spring struts wheel carriers control arms steering arms track rods front axle cross member fron...

Page 371: ...n at the cost of the refusing party If the decision contradicts the guideline we recommend that a memorandum be drawn up on the point and that it be countersigned by the expert Externally undamaged po...

Page 372: ...in the passenger s compartment Airbag units must be stored in accordance with the second ordinance of the explosives legislation This ordinance stipulates that small quantities of materials and objec...

Page 373: ...ecessary in order to interrupt the power supply to the airbag system and to ensure it is not triggered accidentally This is necessary in order to interrupt the power supply to the airbag system and to...

Page 374: ...spinning away e g of the entire unit Burns caused by touching the hot surfaces of a triggered unit Damage to hearing due to the explosion when gas is released Irritation caused by breathing in explosi...

Page 375: ...disconnect the plug connection Transport in transport packaging Forbidden in passenger compartment Storage in the workshop max 10 kg 100 driver s or 50 passenger s airbags security against theft The...

Page 376: ...n for at least 10 seconds The fault memory must be cleared following a fault in the airbag system and after it has been remedied The replacement of a component must be noted in the Guarantee and Maint...

Page 377: ...de airbag is triggered After triggering of belt tensioner After triggering of a belt tensioner driver s and or passenger s unit After triggering one or more air bag units driver s passenger s and or s...

Page 378: ...rature probe into centre vent Measure ambient temperature Open all dashboard vents Switch ignition on Press circulation button Set temperature control to maximum cooling Switch fresh air blower to sta...

Page 379: ...pressure in cold circuit as a function of ambient temperature Low pressure in cold circuit as a function of ambient temperature einordnung Centre vent temperature as a function of ambient temperature...

Page 380: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Low pressure in cold circuit as a function of ambient temperature 317...

Page 381: ...h a maximum transmission power of 10 W Porsche permits the installation and operation of two way radios over 10 W for the radio services listed below under the following preconditions The transmission...

Page 382: ...antenna or with an external antenna that is incorrectly installed or defective In this case malfunctions of the electronic vehicle systems and damage to health cannot be entirely ruled out In general...

Page 383: ...tandard alarm system M 590 lid release locks is also standard equipment in these vehicles top of page Removing alarm siren and tilt sensor 1 Remove cover for fluid reservoir air conditioning 2 Pull of...

Page 384: ...t M numbers and establish the expected closed circuit current with the aid of the attached table Measurement 1 Open the front luggage compartment 2 Close the lower part of the lock of the luggage comp...

Page 385: ...g device connected pull off the fuses of terminal 30 and the relays successively When disconnecting observe the display values of the measuring device to detect a reduction in current After troublesho...

Page 386: ...n computer 0 7 PCM2 as from MY 03 2 8 Telephone as from MY 03 0 2 Both seat memeories M No 537 1 6 Climatronic M No 573 0 03 Standard production vehicle Total Approx 19 Additional equipment Total Appr...

Page 387: ...intained according the versions in this chapter Besides the start function the battery also has the tasks of buffer and supplier of electrical energy for the entire vehicle electrical system top of pa...

Page 388: ...ing opening Note First aid Rinse acid splashes to the eyes immediately with clear water for a few minutes Consult a doctor immediately Neutralise acid splashes to the skin or clothing immediately with...

Page 389: ...rid plates of the battery Damage to the battery housing through the retaining bracket possible acid leak high subsequent costs Inadequate crash safety Functioning of central venting Note Batteries of...

Page 390: ...on nut on the positive battery terminal and remove terminal 6 Pull off vent hose A and fix in a suitable position with insulating tape 7 Unscrew fastening screw B 8 Remove battery top of page Install...

Page 391: ...bserved when handling battery acids Wear suitable protective clothing and protective glasses Only illuminate the inside of the battery with a torch Never illuminate the inside of the battery with a na...

Page 392: ...commercially available battery acid tester Gr 3 0 6 Workshop Equipment Manual The electrolyte gravity test provides information about the state of the battery in connection with the battery load test...

Page 393: ...trolyte in cell 4 is too low Example 2 The gravity of electrolyte in cells 4 and 5 is too low The specific gravity of electrolyte deviations between the battery cells is larger than 0 03 kg dm If the...

Page 394: ...ending on the battery capacity operating instructions of test device The load test currents can also be referred to in the following tables 4 Carry out the battery load test according to the operating...

Page 395: ...line of the battery charging device to the positive terminal of the battery 5 Connect negative line of the battery charging device to the negative terminal of the battery 6 Set the charge current on...

Page 396: ...ent at maximum 5 of the battery capacity ie with a 80 Ah battery the charge current is a max 4 A 8 Charge battery 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Charg...

Page 397: ...connected The transferring of the electricity supply to the release motors is carried out by a change over relay mini relay located on the rearside of the fuse box Should the door be locked alarm prot...

Page 398: ...ropriate electricity source e g separate vehicle battery 6 Actuate the cover switch on the side member panel and open the cover 7 Disconnect auxiliary wire and push the emergency power contact back in...

Page 399: ...w securing it to the body per side is still available as a spare part Only certain combinations of front axle cross member attachment F1 or F2 to the body are permitted F2 2 fastening points as of mod...

Page 400: ...le combination Permissible combinations Front axle cross member with one fastening bore F1 and body with one fastening point K1 Standard construction up to end model 01 Front axle cross member with tw...

Page 401: ...ombination front axle cross member with two fastening bores and F2 and body with one fastening point K1 is not possible 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung...

Page 402: ...Designation of the special tool Explanation Spring clamp Commercially available in accordance with Technical Equipment Manual Chapter 2 4 No 12 Clamping range of spring holder up to 165 mm spring dia...

Page 403: ...0 Nm 59 ftlb 2 Stop plate 1 Mount in correct position No 2 and No 7 are identical parts 3 Spring strut mount 1 The RI or LE code for the right or left side respectively is stamped on the top of the sp...

Page 404: ...ber is stamped on the bottom of the spring seat A cast lug is located on the left spring seat The spring seat must be centred on the vibration damper 14 Washer 1 The washer is inserted in the spring s...

Page 405: ...lines for example 1 x blue and 1 x white Refer to the Parts Catalogue for the allocation B Identification of the coil spring tolerance group load group for determination of the compensation part sprin...

Page 406: ...ring tensioning Never use an impact bolter to loosen or tighten the fastening nut Use commercially available changeover ratchet If the vibration damper has been replaced or the spring seat loosened al...

Page 407: ...p plate 7 as far as they will go into the correct position on the piston rod Vibration damper 3 Place pre tensioned coil spring on the vibration damper 4 Place the mount back up ring spring plate asse...

Page 408: ...nut on the spring strut mount In this way the specified tightening torque can be adhered to exactly It is also possible to counter at the piston rod with countering tool 9630 at the same time 996420...

Page 409: ...ssembly instructions top of page Tools Item Designation of the tool Remarks Spring clamp e g from Klann with spring holder Commercially available clamping range of spring holder up to 165 mm spring di...

Page 410: ...sition spring strut mount 3 2 Stop plate 1 Mount in correct position No 2 and No 6 are identical parts 3 Spring strut mount 1 Remove complete assembly mount with intermediate part No 9 and spring plat...

Page 411: ...1 Fit in correct position groove facing snap ring 13 Snap ring 1 Ensure perfect seating top of page Disassembly and assembly instructions Disassembly CAUTION Danger of injury due to spring tensioning...

Page 412: ...ly The following spring plates compensation parts are available Allocation of the spring plate according to the coil spring tolerance group 1 green line 4 0 mm thick compensation part coloured black 1...

Page 413: ...ion part natural colour C Colour dot colour label to differentiate the vibration damper For the Turbo there is a variant for the USA and a variant for the RoW Vibration damper with Golden colour dot R...

Page 414: ...art spring plate onto the piston rod so that the end of the coil spring lies against the stop of the spring plate 5 Place stop plate in the correct position on the spring strut mount 6 Screw new faste...

Page 415: ...er 8 Tighten the fastening nut once the mount has been correctly positioned and the coil spring lies properly against the stop Tightening torque 58 Nm 43 ftlb Never use an impact bolter to tighten the...

Page 416: ...Danger of injury and material damage through impaired brake function exists if brake discs are damaged during the mounting removal of wheels Use assembly pins in order to exclude any possibility of he...

Page 417: ...in such a way that the strap fastenings are on the inner side of the rim 3 Close the strap fastenings arrow Retighten straps when necessary 4 Stow the collapsible spare wheel in the spare wheel recess...

Page 418: ...ard in the 911 Turbo 996 The steering angle sensor supplies information about the slip angle of the front wheels to the PSM control module intention of driver in relation to direction of travel Steeri...

Page 419: ...ate the steering angle sensor with the front wheels in straight ahead position Calibration description in following text 3 Select the Calibrate steering angle sensor menu with the Porsche System Teste...

Page 420: ...is not correct Check the steering angle sensor actual value in the following cases 1 Suspension alignment when no change has been made to the wheel alignment values 2 As a check after steering angle s...

Page 421: ...index 01 can be installed as replacements for instrument clusters with index 00 Instrument clusters with index 02 are not suitable for replacing instrument clusters with index 01 Variant 3 as from mod...

Page 422: ...e Airbag units are pyrotechnical items and can pose an environmental hazard For this reason non ignited airbag units or entire vehicles must not be disposed of as normal scrap refuse or in other final...

Page 423: ...Use ear protectors Maintain a safety distance by utilising the entire cable length of the ignition tool Do not connect the voltage source until all other preparations are complete Choose a place in fr...

Page 424: ...ting ignition tool Driver s side Connect the ignition device 9257 with the adapter cable 9567 directly to the 2 pin plug of the driver s airbag contact unit under the steering column Passenger s side...

Page 425: ...ion Place the ignition device in front of the vehicle through the door gap Belt tensioner Connect the ignition device 9257 with the adapter cable 9257 3 to the belt tensioner Place the ignition device...

Page 426: ...er s airbags and side airbags and the belt tensioner must be ignited separately Attach the ignition device to a vehicle battery and press the button 996420 996421 996450 996451 996430 996431 996840 99...

Page 427: ...he atmosphere and must be disposed of correctly Due to their chemical composition different refrigerants must not be mixed with each other This also applies for smaller quantities No welding soldering...

Page 428: ...em are not adjustable Sharp objects needles must not be inserted in the nozzle holes Do not install old and new spray nozzles together A Old version adjustable B New version non adjustable 996420 9964...

Page 429: ...cator light W 5 W Additional brake light W 3 W Number plate light C 5 W top of page Installing bulbs CAUTION Danger of damage to property if bulbs are used or handled incorrectly Only bulbs specified...

Page 430: ...ecified in the bulb table may be used Bulbs with a higher wattage may cause damage to the bulb housing To prevent short circuits the load in question must be switched off while bulbs are changed New b...

Page 431: ...ective caps all contact with dust and other materials lubricants must be avoided The optical contacts plug connectors or bushings must not be cleaned Storage packaging transport The optical waveguides...

Page 432: ...de into the vehicle twisted optical guides must be straightened Lateral forces on the optical waveguides must always be avoided during installation of the optical waveguide into the vehicle Repairs De...

Page 433: ...contacts affixed In case of repairs these contacts are engaged in the connector housing Grey and black contacts with identical mechanical dimensions are used Grey contacts are used for the transfer wi...

Page 434: ...s Disconnecting plug connector at PCM Remove PCM 9 911019 Removing and installing control unit PCM2 Disconnecting plug connector at amplifier Remove cover for brake booster Disconnecting connector in...

Page 435: ...g front seat Remove holder for control module for telephone 9 919019 Removing and installing control module for telephone Removing optical contacts on plug side 1 Open the secondary lock with the pres...

Page 436: ...r the primary lock has been raised far enough Conduct a visual check of the locks the connector housing and the contacts for any possible damage and if necessary replace the damaged parts Installing o...

Page 437: ...waveguide check again whether the lock has been completely unlocked Conduct a visual check of the locks the connector housing and the contacts for any possible damage and if necessary replace the dama...

Page 438: ...r diode and one receiver diode is installed in all MOST control modules A transmitter diode of an MOST device is connected to the respeective receiver diode of a second MOST device A circuit is create...

Page 439: ...lifier lead 4 without CD changer B Amplifier lead 5 with CD changer C CD changer without amplifier lead 6 D Telephone lead 2 and in connection with amplifier CD changer lead 3 E Optical waveguide conn...

Page 440: ...al equipment warning and indicator lights check operation Checking the function of electrical equipment as well as the indicator and warning lights Mobile roofs check operation Mobile roofs colon chec...

Page 441: ...system and instruments check operation General maintenance colon Test drive Transmission check operation Check vehicle for unusual handling behaviour vibration and noise Diagnostic system read out or...

Page 442: ...fault memory Change engine oil Changing the engine oil and oil filter Vehicle underside and engine compartment visual inspection for leaks oils and fluids and abrasion lines and hoses Underbody panels...

Page 443: ...ment as well as warning and indicator lights check operation Checking the function of electrical equipment as well as the indicator and warning lights Test drive Remote control front seats foot and pa...

Page 444: ...panels visual inspection for completeness installation and damage Coolant hoses check condition Radiators and air inlets at front visual inspection for external contamination and blockage Coolant chec...

Page 445: ...ecure and functioning properly Checking lid and doors Seat belts check operation and condition Checking seat belts Vehicle lighting check function all headlights check adjustment horn check operation...

Page 446: ...rside and engine compartment visual inspection for leaks oils and fluids and abrasion lines and hoses Underbody panels visual inspection for completeness installation and damage Radiators and air inle...

Page 447: ...as well as the indicator and warning lights Test drive Remote control front seats foot and parking brakes also actuation travel engine clutch steering transmission ParkAssist automatic speed control P...

Page 448: ...t pulley on crankshaft M14 x 1 5 170 126 Flywheel on crankshaft M10 85 63 Drive plate on crankshaft Tiptronic M10 x 1 25 90 67 Drive plate on converter Tiptronic M8 39 29 Plugs of pressure relief valv...

Page 449: ...Nm 22 ftlb initial tightening 170 torque angle replace screw Sprocket wheel central screw on the exhaust camshaft internal serration M12 x 1 5 30 Nm 22 ftlb initial tightening 90 torque angle replace...

Page 450: ...nkcase Assembling the crankcase top of page Tools Item Designation Special tool Explanation A Engine holder Holder P 201 Fasten to the right half of the crankcase cyl 4 6 only mount in connection with...

Page 451: ...1 two threaded bores must be provided in addition Item Designation Special tool Explanation Engine holder adapter Engine holder 9667 Additional fastening of the crankcase via four studs Item Designati...

Page 452: ...threaded part G Assembly fixture for flywheel Retaining device P 238 b H Snap ring pliers Commercially available I Special grease for connecting rod bearings Optimol Optipit 000 043 204 17 J Holder f...

Page 453: ...if the adapter ring is used for the first time No Procedure Instructions 1 Centring adapter on engine holder 2 Centring engine holder 3 Reworking engine holder 4 Fastening adapter on engine holder 5 E...

Page 454: ...bores in the adapter ring using a drill bit 6 5 The adapter ring serves as the drilling template 2 Rework engine holder Drill a pilot hole for an M6 thread on the countersunk points To do this first...

Page 455: ...4 6 6 Mount the second adapter half on crankcase Screw the screw sleeves onto the studs and tighten by hand Screw in connecting screws of the adapter half and tighten with 10 Nm 7 5 ftlb Subsequently...

Page 456: ...2 Holder 1 2a Fastening nut M8 3 Hexagon head bolt M6 x 25 1 4 Hexagon head bolt M6 x 35 1 5 Sensor holder 1 6 Plug 1 Tightening torque 70 Nm 52 ftlb 7 Sealing ring A22 x 27 1 Always replace 8 Thread...

Page 457: ...length 169 mm 19 Dowel sleeve 1 20 Hexagon nut M10 x 1 25 1 Tightening torque 50 Nm 37 ftlb 21 Washer A10 5 1 Replace 22 Fastening nut 1 Replace 23 Washer 1 24 Fastening nut 18 Replace 25 Washer 18 2...

Page 458: ...Tightening torque 50 Nm 37 ftlb 2 Piston 1 Oil 3 Compression spring 1 4 Guide sleeve 1 5 Spacer ring 1 6 Sealing ring A18 x 24 1 Replace 7 omitted 8 omitted 9 omitted 10 Fastening nut M8 1 11 Washer...

Page 459: ...ength 80 mm 29 Stud BM10 x 110 2 Projection length 110 mm 30 Stud 1 Projection length 60 mm 31 Stud BM8 x 22 1 Projection length 22 mm 32 Stud BM8 x 48 1 Projection length 49 mm 33 Stud BM10 x 105 1 P...

Page 460: ...he flywheel Make sure that the pulse sender is not damaged Note If the engine holder special tool adapter ring 9667 is used for the first time 2 threaded bores must be made in addition 3 Mount engine...

Page 461: ...bolt 6 Loosen the 18 hexagon nuts M8 of the housing screw connections 7 Loosen the hexagon nuts wrench size 17 in the left crankcase half cylinder bank 1 3 8 Loosen tension rod bolts from the outside...

Page 462: ...r bank 4 6 2 Check the matching number of the crankcase halves The number is located on the top of the head lug Note There are tolerance groups 0 and 1 3 Allocation of the crankshaft gearwheel and the...

Page 463: ...el arrow 4 Clean crankcase halves thoroughly Check whether there are any foreign objects e g residual sealant in the receiving bores of the tension rod bolts 5 Fit the mounting of the intermediate sha...

Page 464: ...attained replace the intermediate shaft and the paired drive wheel 10 Check the circumferential backlash of the intermediate shaft To do this fasten a gauge holder e g VW 387 to the crankcase parting...

Page 465: ...el pin 14 Check installation position If the mounting is correct the centre of the bearing notch should be on the same level as the sealing surface Note Oil sealing lip Insert crankshaft sealing ring...

Page 466: ...with the intermediate shaft and shift the dumb bell shaft Note Additional O rings are inserted on 4 tension rod bolts of the thrust block fastening thrust blocks 2 3 4 and 5 The 4 tension rod bolts mu...

Page 467: ...serve the A side and B side on the assembly sleeve 9511 Insert the prepared tension rod bolts into the right crankcase half from below as far as they will go and retain in this position Place conical...

Page 468: ...ng ring on the crankcase half with vaseline and insert 22 Prepare crankcase halves of the cylinder bank 1 3 To do this insert the bearing shells of the crankshaft and the intermediate shaft Degrease t...

Page 469: ...rod bolts of thrust blocks 2 3 4 and 5 at the same time having a second person pull the chain upwards through the chain space 23 Remove restraining straps again Note Always replace fastening nuts 24 J...

Page 470: ...ew of the conical sleeve 28 Remove conical sleeve and carefully push round seal to its end position with the B side thick wall of the cylinder sleeve while bracing the bolt head 29 Mount sealing washe...

Page 471: ...rod bolts and position with holder special tool P140 Note When tightening the tension rod bolts without a retaining device 9662 it is essential that a second person braces the bolts The O ring is dama...

Page 472: ...s and tighten to 50 Nm 37 ftlb Note The self locking nuts must always be replaced 37 Fit remaining crankcase screw connections Tighten the hexagon nuts to 23 Nm 17 ftlb 38 Fit belt pulley Check the cy...

Page 473: ...must counter with the special tool 9548 The belt pulley is tightened to 170 Nm 126 ftlb 41 Fit flywheel 42 Check distance Dimension X between toothed ring and pulse sender and adjust if necessary Dime...

Page 474: ...ns includes removing and installing cylinders Tools Removing pistons and cylinders Removing pistons Installing pistons and cylinders top of page Tools 13 10 19 Removing and installing pistons includes...

Page 475: ...For mounting the bushings in the cylinder housing E Spacer Spacing pieces 9651 F Holder for cylinder Set of retaining nuts P 140 G Assembly aid Assembly aid 9500 6 For pre assembly of piston circlips...

Page 476: ...iston Oil running surfaces 3 O ring 104 00x2 00 3 Replace on principle mount with special grease do not twist 4 O ring 110 00x2 50 6 Replace on principle mount with special grease do not twist 5 Pisto...

Page 477: ...Mark the cylinder bank accordingly before removing the cylinder 1 Carefully lift the cylinder with the 3 bushings up and off the pistons Note Mark the pistons using a pen e g 1 2 or 3 2 Lever off pist...

Page 478: ...rs 2 and 5 are mounted onto the connecting rod without bushing The pistons of the outer cylinder 1 3 and 4 6 are preassembled in the cylinder View of the central piston View of the outer pistons 1 Mou...

Page 479: ...is used to position the restraining strap Work quickly when positioning to ensure that the piston rings are not damaged 4 Insert the piston inverted into the assembly sleeve special tool 9657 Quickly...

Page 480: ...on the assembly sleeve 9500 7 with the already premounted piston pin circlip onto the piston pin eye Insert plunger into the conical assembly sleeve When doing so the smaller diameter of the plunger...

Page 481: ...ers Align the bushings in the cylinder The flattened areas must face towards the other bushings in longitudinal direction The recesses on the bushing must align with the bores of the studs Mount the o...

Page 482: ...h piston into the bushing Push the piston restraining strap downwards at the same time during this procedure Check the position of the pistons The large inlet valve recesses on the cylinders must face...

Page 483: ...od can still be mounted 10 Check pistons for correct installation position The large valve recesses must face upwards in the installation position 11 Mount cylinder base seal above the studs 12 Place...

Page 484: ...ston pin circlip push the cylinder up to the spacers 9651 Secure the cylinder with the special tool holder P 140 16 Prepare central bushing Fit new O ring and grease liberally 17 Position the bushing...

Page 485: ...ankcase and the bushing 21 Subsequently press in the central bushing as far as it will go using the handwheel 22 Remove holder P 140 from the studs 23 Remove the spacer 9561 again between the crankcas...

Page 486: ...anation Piston ring pliers Gr 1 No 58 Commercially available refer to Workshop Equipment Manual Chapter 2 4 No 58 For the removing and fixing of the piston rings top of page Removal Note Combustion de...

Page 487: ...ove pistons with piston ring pliers 3 Remove piston rings from piston ring pliers 4 Look for the gap of the oil scraper ring 5 Pull apart the oil scraper spring ring 6 Remove oil scraper spring ring e...

Page 488: ...he piston ring pliers should clasp the piston ring from above Only open the piston ring as much as is needed to remove the piston ring from the groove 3 Remove piston ring from the pliers Relieve the...

Page 489: ...5 Pull apart the oil scraper spring at the gap 6 Remove the oil scraper spring from the third ring groove 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Removal 426...

Page 490: ...Tools Item Designation Special tool Explanation Piston ring pliers Gr 1 No 58 Commercially available refer to Workshop Equipment Manual Chapter 2 4 No 58 For the removing and installing of piston ring...

Page 491: ...ogether oil scraper spring 3 Align the gap of the oil scraper spring 4 Insert piston ring into the piston ring pliers 5 Install piston rings 6 Check that the piston ring is correctly seated and positi...

Page 492: ...This will start the oil scraper ring Place the gap of the oil scraper ring into the middle point of the piston ring pliers Carefully stretch the piston ring with the help of the pliers to a point wher...

Page 493: ...scraper spring is inside the oil scraper ring In terms of the piston ring in the ring groove 2 the twist lock must be on the inside of the gap and the designation TOP must be pointing towards the pist...

Page 494: ...ng ring knurled screw in and out Assembling crankshaft top of page Tools Item Designation of the special tool Explanation A Retainer plate P209 a A1 Pan head screws SP No 928 102 151 01 3 ea B Snap ri...

Page 495: ...Carry out insertion test 6 Spacer ring 1 Warm on heating plate push on up to stop 7 Timing gear 1 Check toothing for wear remove if necessary Note reference number paired with intermediate shaft only...

Page 496: ...g shell half 6 Replace 14 Con rod bolts 12 Check 15 Main bearing shells of bearings 2 to 7 12 Replace 16 Main thrust bearing shells 2 Replace 17 Crankshaft 1 Check for wear carry out sounding test 18...

Page 497: ...eck without fail the elongation of the ring knurled screws If the dimension X 38 3 mm is exceeded the connecting rod bolts must be replaced 11 Check the connecting rods Determine the length of the con...

Page 498: ...measure the groove diameter Object Measured value Screw type Diameter groove 1 7 9 mm 3 ring knurled screw Diameter groove 1 7 9 mm 4 ring knurled screw top of page Pressing ring knurled screw in and...

Page 499: ...g knurled screw by hand into the previous old toothing and then press it in up to the rest 2 Re allocate the con rod cover and the connecting rod and lay to one side top of page Assembling crankshaft...

Page 500: ...numbers of the con rods and the con rod bearing caps must all point to the same side 6 Tighten con rod nuts 7 After the tightening procedure check the con rod bolt for twisting 8 Insert and align new...

Page 501: ...g snap rings are available Part number Thickness mm Identification 901 102 148 00 2 4 blank 901 102 148 01 2 3 tempered blue 901 102 148 02 2 2 tempered yellow brown 901 102 148 03 2 1 black gun metal...

Page 502: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Assembling crankshaft 439...

Page 503: ...Qty Removal Installation 1 Hexagon head bolt M10 x 60 4 Insert the front right hexagon head bolt direction of travel with Loctite 574 Tightening torque 65 Nm 48 ftlb 2 Hexagon head bolt M8 x 55 1 3 H...

Page 504: ...g torque 60 Nm 44 ftlb Counter at the hexagon head bolt when tightening wrench size 15 16 Spacer ring 1 17 Threaded sleeve with hexagon wrench size 24 1 18 Cover plate 1 19 Transmission lever with hex...

Page 505: ...ission lever on to tensioning lever Tightening torque 65 Nm 48 ftlb 2 Insert the front right hexagon head bolt on the bracket with Loctite 574 996420 996421 996450 996451 996620 996621 996650 996651 9...

Page 506: ...overview of the drive belt engine installed Remove drive belt Installation overview of the drive belt engine installed Install drive belt top of page Removal overview of the drive belt engine install...

Page 507: ...ir cleaner assembly 2 Loosen servo pump wheel 3 Relieve drive belt 4 Remove servo pump wheel 5 Remove drive belt top of page Remove drive belt einordnung Removal overview of the drive belt engine inst...

Page 508: ...air flow sensor and remove air cleaner assembly 2 Loosen servo pump wheel d Mark belt travel direction with a coloured pen e Undo the three hexagon head bolts on the servo pump by approx one half tur...

Page 509: ...t is completely relieved f Remove servo pump wheel with drive belt to the rear g Remove the belt from all drive wheels and lift up to remove top of page Installation overview of the drive belt engine...

Page 510: ...belt 2 Position servo pump wheel 3 Tension drive belt 4 Tighten fastening screws on servo pump 5 Install air cleaner assembly top of page einordnung Installation overview of the drive belt engine ins...

Page 511: ...n the servo pump wheel 3 Tension drive belt Note It is absolutely necessary to check that the drive belt is correctly seated on all belt pulleys c To tension the drive belt turn the tensioning roller...

Page 512: ...ftlb 5 Install air cleaner assembly Install air cleaner assembly completely e Attach connector onto mass air flow meter f Tighten the hose clamp on the throttle body g Tighten the M6 x 34 hexagon head...

Page 513: ...mshaft Gr 2 2 2 Workshop Equipment Manual B Special tool holding wrench 9653 For countering the inlet camshaft Gr 2 2 2 Workshop Equipment Manual C Commerically available multiple tooth socket wrench...

Page 514: ...mp with 3 hexagon head bolts M6 x 35 and O ring 1 Replace O ring tightening torque 10 Nm 7 5 ftlb 4 Hexagon head bolt M 6 x 25 2 10 Nm 7 5 ftlb 5 Holder for hydraulic valve 1 6 Hydraulic valve for val...

Page 515: ...5 x 120 with washer for actuating element of inlet camshaft 1 Counter with special tool holding wrench 9653 Replace screw counter with special tool 9653 tightening torque 30 Nm 22 ftlb and 170 torque...

Page 516: ...el collection pipe with injection valves and remove holder for turbochargers 2 Cylinder bank 4 6 Undo holder for turbochargers and remove bypass flap control box on turbocharger 3 Remove ignition coil...

Page 517: ...be removed without tension For cylinder bank 1 3 this means the cams of the exhaust and inlet shaft of cylinder 1 point towards each other Figure 8 1 for cylinder bank 4 6 the cams of the exhaust and...

Page 518: ...screw connection of the camshaft sprockets is loosened To remove the sprocket wheels the actuating element of the inlet camshaft must be countered using special tool holding wrench 9653 and the sproc...

Page 519: ...ng screws are microencapsulated and therefore must be replaced 13 Remove camshaft bearing cap To do so uniformly unscrew the hexagon head bolts of the relevant bearing covers from the inside Remove th...

Page 520: ...led 17 Remove the flat based tappets Pull the flat based tappets upwards out of the camshaft housing In order to avoid confusing the individual flat based tappets they should be placed on a prepared s...

Page 521: ...tappet guides are not damaged Note If screws of strength class 8 8 have been installed these must be replaced by screws of strength class 10 9 3 Mount the 18 hexagon head bolts The bolts are tightened...

Page 522: ...Subsequently install the camshafts Removing and installing camshafts ndash engine removed 996420 996421 996450 996451 996620 996621 996650 996651 einordnung 15 03 23 Installing camshaft housing 459...

Page 523: ...amshaft Gr 2 2 2 Workshop Equipment Manual B Special tool holding wrench 9653 For countering the inlet camshaft Gr 2 2 2 Workshop Equipment Manual C Commerically available multiple tooth socket wrench...

Page 524: ...iner 175219 Removing and installing oil container Remove generator 272219 Removing and installing three phase generator Remove coolant guide housing 1 Cylinder bank 1 3 Undo fuel collection pipe with...

Page 525: ...exagon head bolts M6 and remove the camshaft housing cover If this is stuck it can be loosened by gently tapping with a plastic hammer 8 Fit auxiliary chain tensioner for both cylinder banks Unscrew t...

Page 526: ...the 1st cylinder point towards each other Figure 10 1 the cams of the 4th cylinder point away from eachother each points towards cylinder head outer wall Figure 10 2 Figure 10 1 Overlapping TDC of cy...

Page 527: ...ls at the end of the cylinder bank clutch side on the sealing surface for the valve cover Tighten screws by hand only 13 Insert holding keys Insert the holding keys 9661 1 into the frame according to...

Page 528: ...eal Tighten the hexagon head bolts M6 to 10 Nm 7 5 ftlb 19 Install camshaft housing cover Apply a silicone bead of a maximum 1 5 mm Figure drying time of sealant approx 5 min Put on the camshaft housi...

Page 529: ...injection valves and holder for turbochargers 26 Cylinder bank 4 6 Fit holder for turbochargers and install bypass flap control box on turbocharger Tightening torque of fastening nut M8 25 Nm 19 ftlb...

Page 530: ...ust camshaft Gr 2 2 2 Workshop Equipment Manual B Special tool holding wrench 9653 For countering the inlet camshaft Gr 2 2 2 Workshop Equipment Manual C Commerically available multiple tooth socket w...

Page 531: ...ing the camshafts timing Preliminary work Camshafts installed Removing and installing camshafts ndash engine removed Spark plugs removed 032000 Removing spark plugs 1 Unscrew camshaft sprockets To und...

Page 532: ...asurement on the piston crown is possible 4 To set the timing the respective cylinder side must be positioned to overlapping TDC For this purpose turn the engine at the belt pulley of the crankshaft i...

Page 533: ...e adjustment device only slightly It must be possible to move the frame easily by hand 6 Fit adjustment devices Use two screws to fasten the frame of both staking tools at the end of the cylinder bank...

Page 534: ...eft hand stop Use special tool holding wrench 9653 9 Tighten sprocket wheels Check whether the actuating element of the inlet camshaft is still on the left stop Subsequently tighten the sprockets of t...

Page 535: ...the auxiliary chain tensioner To do this relieve the auxiliary chain tensioner and loosen the two fastening screws 17 Reinstall chain tensioner Insert the chain tensioner into the chain housing in ac...

Page 536: ...26 Cylinder bank 4 6 Fit holder for turbochargers and install bypass flap control box on turbocharger Tightening torque of fastening nut M8 25 Nm 19 ftlb 27 Install coolant guide housing 28 Install ge...

Page 537: ...ool Remarks A Special tool holding wrench 9653 1 For countering the exhaust camshaft Gr 2 2 2 Workshop Equipment Manual B Special tool holding wrench 9653 For countering the inlet camshaft Gr 2 2 2 Wo...

Page 538: ...op of page Component overview and tightening torques No Designation Qty Removal Installation 1 Closure cap green 2 Replace insert dry 2 Cover with 3 hexagon head bolts M6 x 20 and O ring 1 Replace O r...

Page 539: ...for sprocket wheel of exhaust camshaft 1 Internal serration screw M12 x 1 5 counter with special tool holding wrench 9653 1 do not interchange drive plate Height left right is different Replace screw...

Page 540: ...00119 Removing and installing engine Remove rear muffler Remove the oil container 175219 Removing and installing oil container Remove generator 272219 Removing and installing three phase generator Rem...

Page 541: ...ver Unscrew the 15 hexagon head bolts M6 and remove the camshaft housing cover If this is stuck it can be loosened by gently tapping with a plastic hammer 8 Check engine position The cylinder side whi...

Page 542: ...is unscrew the two fastening screws of the chain tensioner cover and remove the cover Then remove the chain tensioner 10 Remove guide rail for timing chain Remove the three fastening screws on the sho...

Page 543: ...to be replaced The pan head screws of the oil guide housing can fall into the crankcase when unscewing the use of a solenoid socket wrench insert is therefore recommended The oil guide housing of cyli...

Page 544: ...rust bearing cover up and off 16 Lift camshafts up and out top of page Installing camshafts Note The oil guide housing of cylinder banks 1 3 and 4 6 differ in height Comparative view of oil guide hous...

Page 545: ...engine on the belt pulley of the crankshaft clockwise until the TDC mark on the belt pulley crankshaft side of belt pulley is aligned with the cast lug on the crankshaft housing Note The camshafts are...

Page 546: ...ourth cylinder point away from each other Figure 4 2 Figure 4 1 Position of the camshafts on overlapping of cylinder 1 1 Exhaust camshaft 2 Inlet camshaft Figure 4 2 Position of the camshafts on overl...

Page 547: ...elements must be positioned to the left hand stop Use special tool holding wrench 9653 The hexagon head bolts M12 for the actuating element of the inlet camshaft is to be replaced 10 Place camshaft ad...

Page 548: ...ble for cylinder bank 1 3 and right must be visible for cylinder bank 4 6 Push on the sprocket Push on the drive plate for the oil extraction pump and tighten the new internal serration screw by hand...

Page 549: ...ve lift adjustment Put on holder with both hexagon head bolts M6 x 25 and tighten the screws with tightening torque Tightening torque of the hexagon head bolt M6 8 8 10 Nm 7 5 ftlb 18 Fit the closure...

Page 550: ...cylinder bank 1 3 2 Bearing shell half 1 Replace insert in crankcase half of cylinder bank 1 3 3 Dumb bell shaft 1 Check for true running without any problems it must be possible to shift shaft slight...

Page 551: ...ng should lie opposite the Woodruff key groove 12 Sprocket wheel 1 Check toothing for wear press off if necessary Warm on heating plate push on up to stop Collar points towards intermediate shaft gear...

Page 552: ...er and the heat shields must be removed 63 Removing and installing rear spoiler 1 Remove the side heat shields on the relevant side of the vehicle 2 Disconnect the connecting hose between the air clea...

Page 553: ...heat shield Then press the heat shield out of the studs 6 Undo the rear fastening Unscrew the fastening nut and the fastening screw 7 Remove charge air cooler 8 Remove heat shield To do so unscrew the...

Page 554: ...plug and pull the plug out at the same time Then pull the switch over valve out of the cylinder head WARNING Take care of the coil spring During removal and installation make sure that the coil spring...

Page 555: ...er to position the hydraulic valve a socket with an extension of wrench size 20 may be used 3 Position the two fastening screws and screw them in evenly Tighten screws to 10 Nm 7 5 ftlb 4 Install the...

Page 556: ...ns on the charge air cooler with new O rings and fit them in place The connections must audibly engage 10 Tighten the two sheetmetal nuts on the heat shield Fit rear spoiler again 63 Removing and inst...

Page 557: ...15 70 21 Removing cylinder head Removing cylinder head 15 70 21 Removing cylinder head 494...

Page 558: ...Upper spring retainer of the exhaust spring 6 6 Outer valve spring exhaust valve 6 7 Inner valve spring exhaust valve 6 8 Valve stem seal 6 Replace 9 Lower valve retainer exhaust valve 6 10 Spacer exh...

Page 559: ...g the camshaft housing 1 Remove the seal between the camshaft housing and the cylinder head Do not use the seal again 2 Unscrew cylinder head Unscrew the twelve internal serration screws in turn steps...

Page 560: ...lace cylinder head in position Uniformly push the cylinder head over the studs from above When doing so make sure that the sealing surface is not damaged Hand tighten the multiple tooth nuts 3 Tighten...

Page 561: ...0 ftlb Retighten screws with torque angle of 1 x 90 Location Thread Tightening torque Nm ftlb Cylinder head nuts 30 Nm 22 ftlb then loosen 20 Nm 15 0 ftlb then retighten all screws again to 20 Nm 15 0...

Page 562: ...e manifold 3 Tilt the complete air cleaner housing 90 upward and remove to the rear 4 Pull off the connecting hoses between the charge air coolers and the pressure pipe To do this unclip the locking c...

Page 563: ...move oil temperature sensor 8 Remove plug wrench size 19 Undo oil pressure sender Important always counter with a second wrench wrench size 22 when doing so Pull off the electrical plug and unscrew th...

Page 564: ...onnecting hoses between the charge air coolers and pressure pipe with water at the connecting points and fit the hoses The hoses must audibly engage Then recheck whether they are positioned properly b...

Page 565: ...the hot film mass air flow meter To do this push the plug downwards and press on the grooved surface at the sides Then pull the connector up and off Open the omega clip on the left side of the air cle...

Page 566: ...removing the spring clip 5 hose clamp 3 hexagon head bolts 1 2 and electrical plug 4 Pull off vacuum hose to the control valve 7 Pull off electrical plug Undo the fastening screws and remove the throt...

Page 567: ...The hoses must audibly engage Then re check whether they are positioned properly by tilting and pulling on them 4 Install air cleaner assembly 24 25 19 install and remove air cleaner Location Thread T...

Page 568: ...17 28 19 Removing and installing check valve engine installed Removal Installation View of the check valve 17 28 19 Removing and installing check valve engine installed 505...

Page 569: ...tick in any position Replace if necessary 8 Sealing ring 21 89 x 2 62 2 Replace coat with Vaseline 9 Sealing ring 30 x 2 5 1 Replace coat with Vaseline top of page Removal 1 Raise the vehicle at the j...

Page 570: ...calding by hot oil 4 Equip oil drain plug with new sealing ring and tighten Make sure to counter with a wrench when tightening Tightening torque 60 Nm 44 ftlb 5 Undo oil drain plug on the crankcase Un...

Page 571: ...il container DANGER Risk of damage Do not twist the flange 9 Undo the fastening screw M8 x 30 and pull the check valve off the crankcase Push the oil container aside at the same time top of page Insta...

Page 572: ...e oil level 7 Check engine oil level Check engine oil level on the instrument cluster Top up engine oil until the 7th segment of the on board computer display lights up The following conditions must b...

Page 573: ...ntainer Remove intake distributor 244619 Removing and installing intake distributor top of page Removing oil cooler 1 Remove crankcase ventilation tube Unscrew the two M6 screws arrows for this purpos...

Page 574: ...ooler 6 Suck out remaining oil top of page Installing oil cooler Note Always replace the O rings for the oil cooler 1 Replace seals Replace the four O rings arrows between the bracket and oil cooler C...

Page 575: ...ut arrow in position but do not tighten yet Note Always replace the flange seal for the crankcase ventilation tube 5 Replace the flange seal then place the two M6 screws arrows in position and tighten...

Page 576: ...ke distributor 8 Install oil container Removing and installing oil container 9 Check oil level and top up if necessary 032000 Changing engine oil and filter 996420 996421 996450 996451 996620 996621 9...

Page 577: ...l container Removing oil container removal overview Installing oil container Preliminary work 100119 Removing and installing engine top of page Removing oil container removal overview 17 52 19 Removin...

Page 578: ...vent line a Detach return line on the oil container Make sure to counter with a wrench at the oil container b Loosen the hose clamp at the vent line and pull off the vent hose einordnung Removing oil...

Page 579: ...kcase ventilation and oil container fastening e Loosen the hose clamp on the positive crankcase ventilation hose on the engine and pull off the vent hose f Loosen the oil container fastening screw 4 D...

Page 580: ...Installing oil container 1 Tightening fastening screws Tighten the two oil container fastening screws at the side holders Tightening torque 23 Nm 17 ftlb einordnung Installing oil container 517...

Page 581: ...tening c Push on the positive crankcase ventilation hose again and tighten the hose clamp d Position and tighten the oil container fastening screw Tightening torque 23 Nm 17 ftlb 4 Pushing on oil leve...

Page 582: ...line on the oil container Make sure to counter with a wrench at the oil container when doing this h Push on vent hose again and fit the spring band clamp 996420 996421 996450 996451 996620 996621 9966...

Page 583: ...ors must be opened only manually Never open them with tools Manually open drain cocks and drain collect the coolant View of the drain cock CAUTION Risk of damage Never use tools to close the drain coc...

Page 584: ...in coolant Note The engine cooling system is factory filled with a lifetime engine coolant This engine coolant must not be mixed or replaced with other coolants Use only original Porsche coolant when...

Page 585: ...the screen Start function with F8 5 Press the F8 key and follow the further instructions of the Porsche System Tester 2 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung...

Page 586: ...ing screw M6 x 34 a f 13 on the rear side of the air cleaner housing 2 Disconnect the hot film mass air flow meter line of the air cleaner housing Pull off electrical wire connector of the hot film ma...

Page 587: ...removing the intake pipes pull off the connector 5 Pull off the electrical connector on the solenoid hydraulic valve of the cylinder bank 1 3 6 Undo pressure pipe middle by removing the spring clip 5...

Page 588: ...at the same time remove the filter with holder 11 Remove holder for fuel return line on the intake pipe hexagon head bolt M 6 12 Undo three fastening screws on the front intake distributor separation...

Page 589: ...coolant expansion tank 17 Prepare auxiliary hose internal diameter and a length of approx 1 metre 18 Pull off disconnected coolant hose push auxiliary hose onto the supports and collect coolant in a...

Page 590: ...n position of the screw type hose clamp The screw must be installed pointing vertically downwards 4 Install intake pipe Fix new seal onto the separation point intake distributor Place suction line on...

Page 591: ...rear The holder must engage audibly 6 Install fuel hoses 7 Install rear pressure pipe 8 Fit air cleaner assembly 9 Remove hose clamp 10 Fill in coolant 11 Warm engine up to operating temperature Perf...

Page 592: ...624 1 B Commercially available refer to Workshop Equipment Manual Chapter 2 4 Nos 72 and 73 top of page Removal 1 Raise the vehicle at the prescribed jacking points 2 Open engine compartment lid 3 Dis...

Page 593: ...is purpose CAUTION Falling rear muffler The rear muffler is loose after the restraining straps are removed The rear muffler should be held by a second person or supported with a transmission jack 10 P...

Page 594: ...r coolers and the pressure pipe Unclip the locking clips using a screwdriver and pull off the hose Then clip the locking clips in again Undo the right fastening screw on the refrigerant line 16 Remove...

Page 595: ...To do this turn the tensioning roller clockwise hold and simultaneously remove the drive belt from the generator 21 In order to reduce the pressure in the cooling system carefully open the coolant ex...

Page 596: ...Adjust the pressure screw until the mounting point is touching the crankcase or the crash support 25 Separate engine carrier from the engine mounts right and left a f 18 26 Separate engine carrier fr...

Page 597: ...coolant filler hose off the coolant pump 30 Undo fastening screws of the coolant pump 31 Remove coolant pump and dispose of seal top of page Installation 1 Clean sealing surfaces 2 Install a new seal...

Page 598: ...retaining device 9624 1 9 Fasten stabilizer Tightening torque 25 Nm 18 ftlb 10 Install rear mufflers with new seals The seals between the exhaust turbochargers and the rear muffler must be replaced Mo...

Page 599: ...ation position of the drive belt on all drive wheels is correct Check the installation position on the belt pulley from underneath use light source 16 Install pressure pipe Push on vacuum hose to the...

Page 600: ...meter line Open omega clip on the left hand side of the air cleaner housing Insert electrical line of the hot film mass air flow meter Close omega clip 22 Connect battery 23 Enter radio code Note The...

Page 601: ...2 Raise the vehicle at the prescribed support points 3 Remove left front wheel To do this remove the wheel bolts and take the wheel off 4 Remove front underbody cover 5 Remove the front part of the le...

Page 602: ...e Y type distributor WARNING Risk of damage to the coolant pipe when the coolant hose is cut open Do not cut too deeply when cutting open the coolant hose 10 Loosen hose clamp at the inner coolant pip...

Page 603: ...e rear hose clamp on the connection point of the Y type distributor and on the coolant pipe of the middle radiator 4 Re position the hose clamp between the Y type distributor and the left radiator Tig...

Page 604: ...nnections with a lubricant such as Vaseline or spray oil 10 Check whether the locking spring at the radiator flange is properly seated The locking spring must be positioned between the two integral gu...

Page 605: ...heel Tighten the wheel bolts Tightening torque 130 Nm 96 ftlb 16 Fill in coolant and bleed the cooling system in connection with the Porsche System Tester 2 To do this select menu item Special functio...

Page 606: ...hicle in a clearly visible position see Figure Ensure good ventilation in the work area e g open window switch on exhauster Secure vehicle with warning sign Item Designation Source Remarks A Connectin...

Page 607: ...a f 13 mm 3 Connect connecting lead 9559 with special tool pressure gauge P 378a a f 17 union nut and manually attach the line to the test connection of the fuel supply line arrow Procedure when the...

Page 608: ...essure Target test values when engine is idling 3 3 0 2 bar 10 Loosen the union nuts of the connecting cable 9559 for the special tool pressure gauge P 378a on the test connection and remove special t...

Page 609: ...tach or mount a warning notice on the vehicle in a clearly visible position see Figure Secure vehicle with warning sign CAUTION Coolant is hazardous to the health and irritates the skin Danger of scal...

Page 610: ...nsor 1 3 Sealing ring 1 Replace 4 Tank closure 1 Grease sealing ring with Vaseline 5 Hexagon head bolt M6 x 12 2 Tightening torque 10 Nm 7 5 ftlb 6 Fuel evaporative valve 1 7 Vent hose 1 8 Filler neck...

Page 611: ...tre position front wheels straight ahead and lock it with the steering wheel holder arrow Note Before disconnecting the battery observe the work instructions 9 Work instructions after disconnecting th...

Page 612: ...ive and 39 02 19 Removing and installing cardan shaft 7 Drain coolant To do this clamp shut the coolant hoses between the cardan tunnel and the engine including the black vent line over the left coola...

Page 613: ...out carefully The open surge flap must not be damaged when pulling out the filler neck Close the opening in the fuel tank e g with the cap of a spray can 12 Loosen universal joint steering shaft arro...

Page 614: ...sion subframe Undo the six hexagon head bolts at the front and rear Items 2 6 and 7 and lower complete suspension subframe by approx 15 cm 16 Disconnect all coolant lines To do this undo the four spri...

Page 615: ...from the body To do this pull back the tab on each holder 2 press the entire holder forwards and up 3 and remove the pipe package together with both holders to the rear Remove pipes from the plastic h...

Page 616: ...torque 23 Nm 17 ftlb 3 Insert fuel level sensor with new seal into fuel tank Position and tighten new union nut Fit lines and plugs After assembly secure union nut with a spot of hot melt adhesive Fi...

Page 617: ...vent line on the distributor hose in the left front wheel well Item 2 and four clamps for coolant pipes Item 4 in next figure 8 Mount four pipe holders using two M6 hexagon head bolts and two M6 hexag...

Page 618: ...t hexagon with an open ended wrench Connect cable plug to sensor of the headlight beam adjustment right arrow Tightening torque of M10 hexagon nut 46 Nm 34 ftlb Note Replace hexagon head bolts for fas...

Page 619: ...t wheel drive with the help of a second person 39 88 19 Removing and Installing front wheel drive Note To facilitate installation apply a thin coat of silicone spray to the filler neck in the fitting...

Page 620: ...ork instructions after disconnecting the battery 23 Remove steering wheel holder 24 Check wheel arch values In the case of deviations perform a suspension alignment if necesary and adjust 44 Wheels ti...

Page 621: ...Wheel to wheel hub M14 x 1 5 130 996410 996411 996420 996421 996450 996451 996430 996431 996610 996611 einordnung Tightening torques for front axle and fuel tank 558...

Page 622: ...he fuel level sensor system 3 Remove fuel level sensor Rep Gr 20 66 19 Removing and installing fuel pump 4 Using a fuel extractor completely drain the fuel tank through the fuel level sensor opening F...

Page 623: ...transmission unit 10 10 removing and installing engine 2 Remove coolant expansion tank Undo the hexagon nut Disconnect electrical plug connection from the sensor for coolant level indicator Pull cool...

Page 624: ...el Protect the open lines against dirt 5 Guide the fuel return line out of the line holder and remove top of page Installation 1 Guide the fuel return line into the line holder and insert 2 Connect th...

Page 625: ...nto the guide rails and fasten 5 Attach connector from the sensor for the coolant level indicator 6 Install engine again 10 removing and installing engine 996420 996421 996450 996451 996620 996621 996...

Page 626: ...lter top of page Removing fuel filter 1 Disconnect plug on the hot film mass air flow meter To do this push the plug downwards and press the grooved surface at the sides Pull the plug up and off at th...

Page 627: ...ing 4 Undo hose clamp Undo the hose clamp arrow between the air cleaner housing and the intake pipe 5 Tilt air cleaner housing outwards To do this tilt the housing upwards on the right by 90 and then...

Page 628: ...ect the plug connection and collect the residual fuel Protect open lines against dirt 10 Remove fuel filter with holder To to this bend the retaining clip upward as shown arrow and simultaneously remo...

Page 629: ...the fuel filter with holder on the coolant expansion tank again and press it down at rear The holder must engage audibly 14 Connect plug connector of the fuel supply line The plug must engage audibly...

Page 630: ...right by approx 90 and push the rubber hose over the flange Then swivel downwards by 90 19 Tighten the fastening screw M6x34 to 10 Nm 7 5 ftlb 20 Tighten the hose clamp on the connecting hose Reconnec...

Page 631: ...see Figure Only carry out checking when engine is standing still Ensure good ventilation in the work area e g open window switch on exhauster Secure vehicle with warning sign Item Designation Source R...

Page 632: ...ng Collect emerging residual fuel with a cloth for example 5 Insert receptacle into the open end of the hose for the special tool connection hose 9507 and connect with the rapid action coupling of the...

Page 633: ...st engage audibly by pulling the line apart 10 Install underside panels 911 Carrera 996 51 90 19 Removing and installing underside panels 11 Switch off ignition switch off Porsche System Tester and di...

Page 634: ...a 1 Suck refrigerant out of the charging valves in the luggage compartment 2 Open the engine compartment lid and disconnect the refrigerant lines from the fuel cooler Immediately seal the openings wit...

Page 635: ...refrigerant lines and fasten on to fuel cooler 2 Fasten holding clamp of the fuel cooler CAUTION Always counter at the fuel lines when fastening them 3 Fastening fuel lines 4 Drain and fill the refri...

Page 636: ...ear spoiler includes rear end lower central heat shield and bumper 635519 Removing and installing rear spoiler 1 Remove wheel housing liner Serv No 5369 2 Pull the two connecting hoses off the charge...

Page 637: ...ng screws on the charge air cooler two at rear two at heat shield and three in wheel housing Remove charge air cooler 4 Unscrew cover panel 5 Unclip intake pipe Unclip the pipe at the bottom and lift...

Page 638: ...all intake pipe catches First insert the pipe into the duct and then press evenly into the body 4 Reinstall cover panel Insert the cover panel in the wheel well and tighten the seven fastening screws...

Page 639: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing air guide for charge air cooling 576...

Page 640: ...r of burns Parts of the exhaust system can be extremely hot Do not begin work until the exhaust system has cooled down 1 Remove charge air cooler To do this disconnect both hose connections on the cha...

Page 641: ...e uppermost screw connection Make sure to counter with an open ring wrench when doing this Then open the support of the turbocharger 8 Pull off vacuum line Pull off the vacuum line on the control box...

Page 642: ...converter 12 Unscrew exhaust manifold Unscrew the nine fastening screws for this purpose Remove turbocharger with exhaust manifold 13 Open separation point between turbocharger and exhaust manifold to...

Page 643: ...n the nine fastening screws on the cylinder head by hand and tighten in two stages First stage 25 Nm 18 ftlb Second stage 33 Nm 24 ftlb Tightening occurs in two stages first 25 Nm 18 ftlb then 33 Nm 2...

Page 644: ...shield Move heat shield into installation position again and tighten the two sheetmetal nuts 7 Push the pressure pipe back onto the turbocharger and tighten the hose clamp 8 Install charge air cooler...

Page 645: ...tening torque Nm ftlb Turbocharger on the exhaust manifold M8 23 17 ftlb Exhaust manifold on the cylinder head 1 stage 2 stage 25 19 ftlb 33 24 5 ftlb Turbocharger on the exhaust catalytic converter M...

Page 646: ...lever out the retaining clip on the top of the charge air cooler and pull the hose out 2 Pull the lower connecting hose off the charge air cooler To do so lever the retaining clip out and pull the hos...

Page 647: ...el well all to 23 Nm 17 ftlb 4 Tighten the front fastening nut and the fastening screw to 23 Nm 17 ftlb Supply the two hose connections on the charge air cooler with new O rings and fit them in place...

Page 648: ...6 Item Designation of the special tool Explanation A Dial gauge holder VW 387 B Tester 9160 1 C Pressure gauge 9103 2 Use boost pressure gauge from 944 Turbo top of page Check and adjust cylinder bank...

Page 649: ...Widen vacuum hose a little and spray in e g silicone spray at the same time Pull off vacuum hose 6 Connect connecting piece shop made and Tecalan line shop made onto the control box and connect with...

Page 650: ...ke tracer pin shop made The tracer pin must be bent accordingly in the area of the deflector plate 3 Carry out checking and adjusting using the same method used on cylinder bank 1 3 996420 996421 9964...

Page 651: ...he exhaust system has cooled down or wear suitable protective gloves 1 Remove safety bracket on the push rod To do so carefully pull off the safety bracket with a screwdriver 2 Loosen and then unscrew...

Page 652: ...ox into the bypass flap release 2 Secure the control box by screwing in and tightening the two holder screws Tightening torque 10 Nm 7 5 ftlb 3 Screw the nut on the push rod 4 Adjust the control box C...

Page 653: ...6 Fit the safety bracket again and check for correct seating 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing bypass flap control box on the turbocharger 590...

Page 654: ...extremely hot Do not begin work until the exhaust system has cooled down or wear suitable protective gloves WARNING Danger of fire The heat shield should not be bent or deformed Bent or deformed heat...

Page 655: ...lines arrows a f 17 and pull the lines out of the oil container by removing the M6 screw arrow from the oil line holder Oil line holder 5 Unscrew both fastening screws hexagon socket a f 6 arrows 6 Re...

Page 656: ...e the lower union nut of the oil line lower arrow in position on the oil container 2 Fasten the oil container using the two hexagon socket head bolts a f 6 arrows Tightening torque 23 Nm 17 ftlb 3 Pla...

Page 657: ...Insert the drain plug arrow and the sealing ring Tightening torque 30 Nm 22 ftlb 7 Installing heat shield 635019 Removing and installing rear bumper 8 Check oil level and top up if necessary 032000 Ch...

Page 658: ...nstallation top of page Tools Item Designation of the special tool Explanation A Retaining device 9624 1 B Commercially available refer to Workshop Equipment Manual Chapter 2 4 Nos 72 and 73 top of pa...

Page 659: ...ump gear 1 Grease with Optipit 5 Oil pump gear 2 Grease with Optipit 6 O ring Replace apply a thin coat of Vaseline 7 Bracket 8 O ring 28 0 x 4 5 4 Replace coat with coolant 9 Connection fitting 2 10...

Page 660: ...e rear muffler is loose after the restraining straps are removed The rear muffler should be held by a second person or supported with a transmission jack 10 Push restraining straps out of the holder P...

Page 661: ...re pipe Unclip the locking clips using a screwdriver and pull off the hose Then clip the locking clips in again 16 In order to remove the pressure pipe loosen the hose clamps and hexagon head bolts Pu...

Page 662: ...e Wear protective gloves Collect emerging Pentosin Protect the line against dirt and scratches with a cap If hoses come into contact with Pentosin clean them thoroughly without delay 24 Insert tool be...

Page 663: ...sor and set it down with the hoses connected 28 Disconnect the fuel lines on the fuel cooler Make sure to counter with a wrench when doing this 29 Loosen hose clamps on the intake distributor and pivo...

Page 664: ...oses Lever off the locking clip for this purpose 33 Refit the locking clip on the coolant neck 34 Remove bracket for generator Undo hexagon head bolts 35 Loosen coolant neck 36 Undo coolant hoses over...

Page 665: ...lling make sure not to damage the bellows on the lower joint 38 Support the engine transmission unit Fasten special tool retaining device 9624 1 on the take up points of the stabilizer mounts The pres...

Page 666: ...upply line from the bracket right hand side 43 Detach the oil supply lines from the bracket left hand side 44 Remove auxiliary screw again 45 Remove complete bracket Simultaneously pull off coolant ho...

Page 667: ...the receiving bores for the dowel pins 2 Insert oil pump gears in the housing The all round groove of the outer oil pump gears must face the oil pump cover 3 Fasten oil pump cover When tightening simu...

Page 668: ...7 Provisionally fasten the bracket using an auxiliary screw The auxiliary screw can be removed again once the oil lines and coolant hoses have been fastened Note Otherwise the bracket is held only by...

Page 669: ...nt to facilitate fitting Note If incorrectly positioned the generator bracket would make contact and cause leaks 12 Remove auxiliary screw 13 Fasten engine carrier Tightening torque 65 Nm 48 ftlb 14 F...

Page 670: ...he heat shields over the studs of the exhaust turbocharger Fit new hexagon nuts Tightening torque 30 Nm 22 ftlb 19 Tighten restraining straps on the rear muffler Tightening torque 15 Nm 11 0 ftlb 20 F...

Page 671: ...heck whether it is fitted properly by tilting and pulling on it 25 Fit air conditioning compressor Do not forget the spacer sleeve 26 Install throttle body 27 Install generator 28 Install hydraulic pu...

Page 672: ...e pipe 2 Press the button on the plug and pull off the plug at the same time top of page Installation 1 Fasten pressure sensor with a new hexagon head bolt M6 x 16 and tighten to 10 Nm 7 5 ftlb 2 Fit...

Page 673: ...24 00 33 Completing the vacuum connections 24 00 33 Completing the vacuum connections 610...

Page 674: ...ng air valve hose 6 Pipe 5 x 1 x 250 7 Curved hose 8 Pipe 5 x 1 x 245 9 Four way branch piece 10 Pipe 5 x 1 x 250 11 Three way branch piece 12 Pipe 4 x 1 13 Distributor pipe 14 Vacuum accumulator 15 C...

Page 675: ...1 x 500 20 Pipe 4 x 1 x 500 21 Curved protective hose 22 Check valve Note When fitting the hosing it is prohibited to use spray oil Soap suds may be used to make fitting easier 996420 996421 996450 9...

Page 676: ...ter To do this push the plug downwards and press the grooved surface at the sides Pull the plug up and off at the same time 2 Pull off the connecting hose between the left turbocharger and the intake...

Page 677: ...ousing to the left by approx 90 6 Unclip the hot film mass air flow meter cable Open the omega clip on the left side of the air cleaner housing and take out the cable Take the air cleaner housing out...

Page 678: ...ss air flow sensor cable To do this insert the cable into the omega clip on the left air cleaner housing side and then close the clip 3 Place the air cleaner housing in the engine compartment as shown...

Page 679: ...onnect the plug on the hot film mass air flow sensor The plug must engage audibly 6 Attach the connecting hose between the left turbocharger and the intake distributor The hose must engage audibly 996...

Page 680: ...etach the holder over the air conditioning compressor Unscrew the M6 screw on the holder for this purpose 4 Undo the hose of the Y shaped pressure pipe To do so undo the spring band clamp arrow and pu...

Page 681: ...ghten the four M6 screws arrows Tightening torque of M6 screws 10 Nm 7 5 ftlb 3 Position the Y shaped pressure pipe with the rubber air cowl on the throttle body connect the vacuum hose 3 and fasten t...

Page 682: ...pressure hoses between the charge air coolers and the Y shaped pressure pipe the pressure hoses must engage audibly 7 Install air cleaner housing Removing and installing air cleaner 996420 996421 996...

Page 683: ...age Tools Item Designation of the special tool Explanation Plug 9264 6 Rubber sleeve belongs to the scope of delivery of special tool 9264 6 top of page Leak test 1 Undo fastening screw M6 x 34 on the...

Page 684: ...tool 9264 6 onto the plug 5 Insert plug with rubber sleeve into the sealing bellows and fasten with the original hose clamp 6 Generate a pressure of approx 0 5 bar Larger leaks are very easy to hear o...

Page 685: ...sassembling and assembling intake distributor top of page Removing intake distributor 1 Remove the secondary air pump Removing and installing secondary air pump 2 Undo the throttle body connections Re...

Page 686: ...6 Undo the holder of the fuel return line Unscrew the M6 screw arrow for this purpose 7 Connect the connector of the overrun air valve arrow and pull off the two vacuum hoses arrow 8 Remove the overru...

Page 687: ...e sealed foreign objects 12 Pull the intake distributor out of the rubber sleeves and lay to one side top of page Installing intake distributor Note Check rubber sleeves and replace if necessary 1 Coa...

Page 688: ...e 5 Install the overrun air valve module 6 Connect the connector of the overrun air valve module top arrow and push on the two vacuum hoses bottom arrow 7 Fasten the holder of the fuel return line Pos...

Page 689: ...the upper box of the distributor pipe and fasten the hose clamps arrows 11 Fasten the throttle body connections Removing and installing throttle body Engine installed 12 Install secondary air pump Rem...

Page 690: ...Disassembling and assembling intake distributor Disassembling the intake distributor Vacuum lines top of page Disassembling the intake distributor 24 46 37 Disassembling and assembling intake distrib...

Page 691: ...100 6 Throttle with E gas actuator 7 Fastening screws M6 x 50 8 Hexagon head bolt M6 x 12 9 Hexagon head bolts M6 x 12 10 Hexagon head bolts M6 x 18 11 Holder for intake air distributor pipe 12 Strain...

Page 692: ...on to the distributor pipe Then remove the distributor pipe 3 Open the two hose clamps on the closure caps with strut and remove the strut 4 Disconnect the vacuum lines top of page Vacuum lines 1 Rec...

Page 693: ...for secondary air 16 Fuel pressure regulator 17 Electric switch over valve for secondary air 18 Pipe 4 x 1 x 350 19 Pipe 4 x 1 x 500 20 Pipe 4 x 1 x 500 21 Curved protective hose 22 Check valve Note W...

Page 694: ...and connector Cleanliness in the housing of the plug connections is of utmost importance for the function of the oxygen sensor Particles of dirt can impair the function of the oxygen sensor Therefore...

Page 695: ...s oxygen sensors on the right side 1 Oxygen sensor in front of catalytic converter on the right side 2 Oxygen sensor behind catalytic converter on the right side Oxgen sensor plug 1 Plug for sensor in...

Page 696: ...sensor 4 Undo and unscrew oxygen sensor with a spanner or an open ring wrench a f 22 Oxygen sensor right side 1 Remove air cleaner housing Removing and installing air cleaner 2 Separate the rectangul...

Page 697: ...en oxygen sensor with conventional open ring wrench Hazet 4681 1 and torque wrench Tightening torque 55 5 Nm 41 4 0 ftlb 3 Lay oxygen sensor wire and fix in the sheetmetal clips and wire retainers on...

Page 698: ...est is 1 bar Note The leak test must not be performed on a hot exhaust system as the rubber seals are only functional at temperatures below 200 C top of page Tools Item 1 Plugs for the exhaust system...

Page 699: ...seal turn each handle clockwise or counter clockwise until the tailpipe outlets are air tight by throwing the adapter handle through 90 Note Do not exceed the permissible pressure of 1 bar 2 Connect p...

Page 700: ...ear mufflers Removing rear mufflers Installing rear mufflers top of page Removing rear mufflers Preliminary work Remove rear spoiler rear bumper and centre heat shield Serv No 635519 26 33 19 Removing...

Page 701: ...straps on the rear muffler Unscrew the two hexagon socket screws for this purpose CAUTION Falling rear muffler The rear muffler is loose after the restraining straps are removed A second person should...

Page 702: ...tening nuts on the turbocharger flange on the left and right of the vehicle and tighten to 30 Nm 22 ftlb 3 Tighten tensioning straps Centre the rear muffler and align free of tension Tighten the two h...

Page 703: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing rear mufflers 640...

Page 704: ...the hose Then re clip the locking clips onto the pressure pipe Ensure correct seating 2 Remove switch over valve on the secondary air pump In order to do this press the locking tabs of the holding cl...

Page 705: ...ith two hexagon head bolts M6 x 10 3 Clip switch over valve onto the secondary air pump housing 4 Fix a new O ring onto the right pressure hose and coat the O ring and take up bore with plenty of wate...

Page 706: ...ect the electrical plug connection on the air flow sensor and remove the complete air cleaner assembly 5 Remove the pressure pipe to the throttle body 6 Relieve the drive belt at the tensioning pulley...

Page 707: ...34 ftlb 4 Install air flow sensor with air cleaner assembly and connect battery 5 Perform a function test top of page Undoing and tightening the belt pulley Note The belt pulley can be undone or tight...

Page 708: ...ailable tools No 32 1 3 Counter with a double ring wrench when tightening with the a f 17 multiple tooth adapter 4 The shaft is tightened to the prescribed tightening torque of 80 5 Nm 59 3 5 ftlb usi...

Page 709: ...and installing bracket for generator Removing bracket for generator Installing bracket for generator top of page Removing bracket for generator Removal CAUTION 27 27 19 Removing and installing bracket...

Page 710: ...mass air flow meter 3 Removing drive belt 137819 Removing and installing drive belt engine installed 4 Unclip the cable from the hot film air flow meter on the expansion tank of the hydraulic pump and...

Page 711: ...to the front screw To do this the two hose clamps must be removed Note Do not open air conditioning system 9 Remove the compressor Disconnect the electrical connection on the compressor Unplug compre...

Page 712: ...h Vaseline when assembling the bracket for the generator Tightening torque of the three screws 23 Nm 17 ftlb top of page Installing bracket for generator 1 Install bracket for the generator Replace th...

Page 713: ...the retaining clip arrow into the groove provided as shown Replace the O ring on the coolant hose 5 Push on coolant hose Align the connection neck of the coolant hose as shown in the illustration lug...

Page 714: ...the expansion tank 23 Nm 17 ftlb 10 Refit oil filler neck and clip the cable from the hot film mass air flow meter into the holder on the hydraulic expansion tank 11 Install drive belt 137819 Removin...

Page 715: ...at the solenoid switch is facing in the direction of the halfshaft 6 Remove starter in a downward direction top of page Installing the starter 1 Install and fasten starter Fasten B lead from the batte...

Page 716: ...h sides of the vehicle top of page Removing hall sender Preliminary work Remove rear spoiler 635519 Removing and installing rear spoiler 1 Remove charge air cooler Removing and installing the charge a...

Page 717: ...essary 5 Unscrew hexagon socket head bolt on hall sender 6 Remove the hall sender top of page Installing hall sender Note The hexagon socket head bolt is micro encapsulated and so must always be repla...

Page 718: ...shield See partial description in chapter 635019 Removing and installing rear bumper Sheetmetal nuts on heat shield 5 Install charge air cooler Removing and installing the charge air cooler 6 Install...

Page 719: ...tool Explanation A Spark plug wrench Workshop Equipment Manual Chapter 2 4 No 1 and extension no 15 Note Only this spark plug wrench has been tested and approved 1 Remove rear spoiler and centre heat...

Page 720: ...s for this purpose 6 Undo hexagon socket head bolts arrows 7 Pull off the plug coils and detach them to the side with connected cables 8 Screw out spark plugs with commercially available tool S9706 to...

Page 721: ...all the shields above the exhaust system 7 Reinstall charge air cooler 8 Fit rear spoiler 635519 Removing and installing rear spoiler 9 Lower vehicle Location Thread Tightening torque Nm ftlb Plug coi...

Page 722: ...nscrew M8 hexagon head bolt upper arrow and remove the knock sensor Installation 2 Clean contact surface for the sensor on the engine block Note In order to guarantee the proper function of the knock...

Page 723: ...tube Unscrew the union nut arrow for this purpose 3 Remove crankcase ventilation tube Unscrew the two M6 screws arrows for this purpose 4 Disconnect plug lower arrow of the knock sensor and set it asi...

Page 724: ...in and tighten the M8 hexagon head bolt upper arrow with the correct tightening torque Tightening torque 23 Nm 17 ftlb 3 Insert plug lower arrow of the knock sensor 4 Install the crankcase ventilatio...

Page 725: ...d bolts 10 Nm 7 5 ftlb 6 Tighten the union nut arrow with the correct tightening torque Tightening torque 30 Nm 22 ftlb 7 Install the oil container 175219 Removing and installing oil container 996420...

Page 726: ...id level rises In this case the engine must be run for approx 20 seconds immediately prior to the fluid level check If coolant hoses come into contact with Pentosin thoroughly clean them with water IM...

Page 727: ...been run for approx 20 seconds without depressing the clutch pedal remove the plastic return line arrow from the expansion tank To this purpose push the red thrust ring in an axial direction without...

Page 728: ...acing the part ensure thorough cleanliness Loosen all lines on the upper part of the tank Collect Pentosin which runs out of these Replace upper part of tank reconnect the lines and fill with Pentosin...

Page 729: ...id reservoir control module for automatic headlight beam adjustment ALWR 1 Fill supply tank 2 Open bleeder valve on the servo unit arrow Note Make sure that the reservoir is not sucked dry Top up duri...

Page 730: ...The clutch high pressure hydraulic system does not need to be bled in a special manner It is sufficient to actuate the clutch pedal approx 10 times with the engine running The steering hydraulic syste...

Page 731: ...ork from all emerging Pentosin using suitable means If coolant hoses come into contact with Pentosin thoroughly clean them with water immediately top of page Removing clutch pressure hose Requirements...

Page 732: ...brake cable 1 Position the clutch pressure hose 1 by hand on the slave cylinder and screw the hose tight with an open ring or open ended wrench a f 14 Tightening torque 30 Nm 22 ftlb 2 Remove the rub...

Page 733: ...and a new plug in coupling Instructions for the plug in coupling are enclosed in the packaging 4 Clip pressure hose back into the plastic holder 5 Bleeding clutch operation Bleeding clutch operation...

Page 734: ...ning torques Installation top of page Removal 1 Raise vehicle on lifting platform Disconnect battery 2 Actuate the clutch pedal at least 25 times with the engine switched off so that the system is dep...

Page 735: ...ive shaft and release the drive shaft at the transmission flange Note Take care when handling Pentosin Wear protective glasses gloves and protective clothing If coolant hoses come into contact with Pe...

Page 736: ...lly available open socket wrench adapter Observe Workshop Equipment Manual Chapter 2 4 No 98 1 Note The tool for unlocking the return line is the tool already familiar from the 986 996 It was used the...

Page 737: ...lever 3 Insert the clutch slave cylinder into the vehicle with the pushrod facing towards the transmission and turn it into its installation position 4 Fasten the transmission slave cylinder bracket l...

Page 738: ...rve them without fail Multiple steering operations manoeuvring and or actuating the clutch with the engine switched off change the fluid level in the engine compartment reservoir Fluid level rises In...

Page 739: ...ator Removal Installation top of page Removal 1 Raise vehicle on lifting platform 2 Actuate the clutch pedal at least 25 times with the engine switched off so that the system is depressurised 30 31 19...

Page 740: ...osition using an oil filter strap Use an open ended wrench to tighten the accumulator tightening torque 30 Nm 22 2 ftlbs 2 Install the bracket for the water hoses and clip the hoses into place Align t...

Page 741: ...level check If coolant hoses come into contact with Pentosin thoroughly clean them with water IMMEDIATELY Replace visibly swollen coolant hoses 4 Top up hydraulic fluid Pentosin CHF 11 S in the expan...

Page 742: ...ation 1 Snap ring 1 Remove using pointed nose pliers simultaneously push down pressure plate using a press Ensure correct seating 2 Thrust plate 1 Engage lug twist lock in the opening of a diaphragm s...

Page 743: ...oved under a shop press For this purpose lay the release bearing down on the bottom and press down on the pressure plate from above with a pressure piece e g hardwood block until the snap ring can mov...

Page 744: ...d in the correct order and the spring washer is seated properly 2 Insert release bearing in diaphragm spring plate Engage lug on release bearing twist lock in the opening between two tongues of the di...

Page 745: ...h Tightening torques top of page Tools Item Designation of the special tool Explanation A Toothed segment P201b B Centring mandrel 9102 top of page Removing clutch 1 Remove transmission 34 35 27 Remov...

Page 746: ...ion the special tool toothed segment P201b A on the stud and tighten the pan head screws in several stages and in diametrically opposite sequence Tightening torque 23 Nm 17 ftlb 3 Remove the special t...

Page 747: ...ormation of the thrust plate housing loosen screws in several stages and in diametrically opposite sequence 2 Release bearing 1 Do not wash out the bearing replace loud bearings do not grease the slid...

Page 748: ...alue is measured the clutch drive plate must be replaced With a new clutch drive plate this dimension measures approx 1 7 mm Note It should be noted that the lining wear does not progress in linear fa...

Page 749: ...straight away The term checking includes all necessary subsequent work such as adjusting readjusting correcting and topping up but does not include repairing replacing and reconditioning parts or asse...

Page 750: ...creen washer headlight washer check fluid level and nozzle settings pay attention to antifreeze protection in the winter months Windscreen wiper sol washer system headlight washer All other electrical...

Page 751: ...ce after 20 000 60 000 100 000 140 000 km etc 12 000 36 000 60 000 84 000 mls etc OK Diagnostic system read out fault memory Diagnostic system colon reading out fault memory Change engine oil Changing...

Page 752: ...system headlight washer All other electrical equipment as well as warning and indicator lights check operation Checking the function of electrical equipment as well as the indicator and warning light...

Page 753: ...ing out the next maintenance straight away The term checking includes all necessary subsequent work such as adjusting readjusting correcting and topping up but does not include repairing replacing and...

Page 754: ...nction all headlights check adjustment horn check operation Checking the function of the vehicle s lights Windscreen washer headlight washer check fluid level and nozzle settings pay attention to anti...

Page 755: ...ngine compartment visual inspection for leaks oils and fluids and abrasion lines and hoses Underbody panels visual inspection for completeness installation and damage Power steering check fluid level...

Page 756: ...electrical equipment as well as the indicator and warning lights Test drive Remote control front seats foot and parking brakes also actuation travel engine clutch steering transmission ParkAssist auto...

Page 757: ...er unlocking of luggage compartment Trunk Entrapment has been added to the countries specification C02 for USA and C36 for Canada as of model year 2003 Minor maintenance after 15 000 45 000 75 000 105...

Page 758: ...d level and nozzle settings pay attention to antifreeze protection in the winter months Windscreen wiper sol washer system headlight washer All other electrical equipment as well as warning and indica...

Page 759: ...the torque converter sealing ring top of page Tools Item Designation of the special tool Explanation A Lever VW 681 B Pressure piece 9670 top of page Removing the torque converter sealing ring Removin...

Page 760: ...orque converter sealing ring 1 Thinly coat sealing lip of sealing ring with Vaseline and drive sealing ring home as far as the mounting face with pressure piece 9670 996420 996421 996450 996451 996620...

Page 761: ...special tool Explanation Locating pin 9595 1 long top of page Removing the torque converter 1 Remove engine transmission unit 100119 and remove the transmission Removing and refitting the transmission...

Page 762: ...recess in the converter hub engages in the driver of the impeller and the converter perceptibly slides inward 2 Check installation depth of the converter Installation depth approx 15 mm WARNING If the...

Page 763: ...Polyrib belt check condition Removing and installing drive belt Change engine oil and oil filter Changing the engine oil and oil filter Replace the spark plugs Replacing spark plugs Vehicle underside...

Page 764: ...lapsible wheel check condition and tyre pressure Tyres and spare wheel colon checking condition and tyre pressure Check the door lid locks and safety hooks of the front lid to ensure that they are sec...

Page 765: ...oil and oil filter Replace the spark plugs Replacing spark plugs Vehicle underside and engine compartment visual inspection for leaks oils and fluids and abrasion lines and hoses Underbody panels visu...

Page 766: ...oks of the front lid to ensure that they are secure and functioning properly Checking lid and doors Seat belts check operation and condition Checking seat belts Vehicle lighting check function all hea...

Page 767: ...0 60 000 90 000 120 000 mls etc 48 000 96 000 144 000 192 000 km etc OK Diagnostic system read out fault memory Diagnostic system colon reading out fault memory Polyrib belt check condition Removing a...

Page 768: ...or leaks and damage check suspension Tyres and spare wheel collapsible wheel check condition and tyre pressure Tyres and spare wheel colon checking condition and tyre pressure Check the door lid locks...

Page 769: ...60 000 km etc 24 000 48 000 72 000 96 000 mls etc OK Diagnostic system read out fault memory Diagnostic system colon reading out fault memory Polyrib belt check condition Removing and installing drive...

Page 770: ...collapsible wheel check condition and tyre pressure Tyres and spare wheel colon checking condition and tyre pressure Check the door lid locks and safety hooks of the front lid to ensure that they are...

Page 771: ...ted as of model year 2002 The test item Checking inner unlocking of luggage compartment Trunk Entrapment has been added to the countries specification C02 for USA and C36 for Canada as of model year 2...

Page 772: ...s for leaks and damage Axle joints sol drive shafts Exhaust system visual inspection for leaks and damage check suspension Tyres and spare wheel collapsible wheel check condition and tyre pressure Tyr...

Page 773: ...crew and drain plug and drain the oil with the vehicle horizontal 3 Clean the drain plug and filler screw 4 Replace sealing ring for drain plug and tighten to 30 Nm 22 ftlb 5 Fill with oil up to the b...

Page 774: ...ng shift console Removing shift console Installing shift console Tightening torques top of page Tools Item Designation of the special tool Explanation 1 Locking bridge 9619 top of page Removing and in...

Page 775: ...er top of page Removing shift console 1 Remove centre console 68 17 19 Removing and installing centre console 2 Move shift lever to neutral position and fix with special tool locking bridge 9619 3 Rem...

Page 776: ...of the shift console Unlock the support bracket sleeves by pressing in both plastic clips 6 Unscrew fastening nuts for the shift console and remove the shift console top of page Installing shift cons...

Page 777: ...and close the adjusters see magnified view The locking sleeves on the adjuster must move to the end position automatically 4 Remove special tool locking bridge 9619 and shift through all gears as a te...

Page 778: ...tening torques top of page Tools Item Designation of the special tool Explanation A Removal tool Commercially available refer to Workshop Equipment Manual Chapter 2 4 No 21 B Locking bridge 9619 top o...

Page 779: ...leeve and can only be replaced together The shift and selector cables must not be excessively bent 1 Remove centre console 68 17 19 Removing and installing centre console 2 Move shift lever to neutral...

Page 780: ...lock the support bracket sleeves by pressing in both plastic clips 6 Remove parking brake console 7 Remove underbody panels middle and rear 8 Use a commercially available removal tool to lever off the...

Page 781: ...ft and selector cables C through the body opening from behind 3 Insert B wire A into the slot of the rubber sleeve B and press sleeve into the body opening 4 Clip support bracket sleeves into the supp...

Page 782: ...ers see enlarged view The locking sleeves on the adjuster must move to the end position automatically 13 Remove special tool locking bridge 9619 and shift through all gears as a test 14 Clip in shift...

Page 783: ...top of page Tools Item Designation of the special tool Explanation Gripper Commercially available Workshop Equipment Manual Chapter 2 4 No 50 top of page Removing transmission 1 Remove engine transmis...

Page 784: ...e and unscrew hexagon head bolt for support 7 Remove bearing cover with commercially available pliers Workshop Equipment Manual Chapter 2 4 No 50 8 Screw a screw M6 into the clutch control shaft and p...

Page 785: ...sion 1 Insert release lever into the release bearing and fix in installation position with suitable adhesive tape 2 Insert closure cap for the pulse sender opening in the correct position in the trans...

Page 786: ...ng cover and support for clutch control shaft top of page Tightening torques Location Thread Tightening torque Nm ftlb Transmission on engine M10 45 33 Air flanges on transmission M6 10 7 5 Slave cyli...

Page 787: ...osure cap for selector force mechanism Tightening torques top of page Tools Item Designation of the special tool Explanation 1 Press out mandrel P 375 top of page Removing and installing closure cap f...

Page 788: ...remove snap ring B A Fastening screw B Snap ring C Closure cap 3 Bore a 3 5 mm hole into the centre of the closure cap coat drill with viscous grease to prevent drilling chips from falling into the tr...

Page 789: ...Note Ensure perfect seating of the snap ring 3 Tighten fastening screw for gear housing Tightening torque 25 Nm 19 ftlb 4 Install engine transmission unit 10 01 19 Removing and installing engine top o...

Page 790: ...correcting and topping up but does not include repairing replacing and reconditioning parts or assemblies Annual maintenance OK Diagnostic system read out fault memory Diagnostic system colon reading...

Page 791: ...al equipment as well as warning and indicator lights check operation Checking the function of electrical equipment as well as the indicator and warning lights Test drive Remote control front seats foo...

Page 792: ...aintenance as of MY 2004 Note Note There is no annual maintenance for vehicles as of model year 2004 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 03 50 00 Annual maintenance a...

Page 793: ...the US market have been added to the Technical Manual for the sake of completeness Note There is no annual maintenance for vehicles as of model year 2004 996420 996421 996450 996451 996620 996621 996...

Page 794: ...g up the ATF Tightening torques top of page Tools Item Special tool designation Remarks Connection hose 9507 1 top of page Checking and topping up the ATF Note Top up only with ATF approved by Porsche...

Page 795: ...and engine idling The air conditioning system and the heater must be switched off The vehicle must stand horizontally 1 Place oil collection pan under the transmission 2 Connect the Porsche System Te...

Page 796: ...Screw special tool 9507 1 A onto the charging valve and top up ATF via the charging valve until excess ATF emerges at the control bore 8 Replace sealing ring for cap nut 9 Screw on cap nut for chargin...

Page 797: ...ial tool designation Remarks Connection hose 9507 1 top of page Replacing ATF fluid Note Top up only with ATF approved by Porsche See Parts Catalogue Filling capacity approx 9 0 litres Change quantity...

Page 798: ...o and tighten the cap nut for the charging valve counter with an open ended wrench 5 Screw off cap nut for the charging valve 6 Screw connection hose 9507 1 A onto charging valve Top up with ATF via t...

Page 799: ...her than 40 C at the start of the test 11 Check the ATF level again and top up if necessary 12 Replace sealing ring for cap nut and screw cap nut onto the charging valve Tightening torque 40 Nm 30 ftl...

Page 800: ...keylock cable A and lift adjuster B up out of the support bracket see enlarged view 1 4 Disengage cable nipple C 5 Disengage selector lever cable D on the selector support To do this slide the locking...

Page 801: ...2 Tighten fastening nuts Tightening torque 10 Nm 7 5 ftlb 3 Insert support bracket sleeve on the selector lever cable in the support bracket on the selector support Make sure the two plastic clips eng...

Page 802: ...eylock cable into the support bracket Make sure the two retaining clips engage properly 9 Install centre console 68 17 19 Removing and installing centre console 10 Install selector knob 37 04 19 Remov...

Page 803: ...lanation A Removal tool Commercially available refer to Workshop Equipment Manual Chapter 2 4 No 21 top of page Removing and installing selector lever cable Removing selector support 1 Remove selector...

Page 804: ...larged view 1 4 Carefully disengage support bracket sleeve C upward out of the selector support Unlock the support bracket sleeves by pressing in both plastic clips see enlarged view 2 5 Remove parkin...

Page 805: ...ogether and pull the support bracket sleeve out of the support bracket 11 Lever the end piece of the selector lever cable off the transmission lever with a commercially available removal tool The sele...

Page 806: ...the slot of the rubber sleeve B and press sleeve into the body opening 4 Press end piece of the selector lever cable onto the ball head on the transmission lever 5 Insert support bracket sleeve on the...

Page 807: ...to park 14 Move selector lever to position P 15 Engage the selector lever cable into the open adjuster and close the adjuster see enlarged view The locking sleeve on the adjuster must move to the end...

Page 808: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tightening torques 745...

Page 809: ...or replacement transmission the adaptation values must be reset with the PST 2 The shifting quality may deteriorate slightly during the adaptation phase of the transmission control module top of page...

Page 810: ...l off vacuum line for flat seat valve on branch piece 5 Disconnect coolant supply hose on pipe 6 Disengage coolant hoses 7 Remove drive belt 137819 8 Rotate engine to TDC mark 9 Unscrew two of the six...

Page 811: ...th special tool holder 9674 13 Unscrew the remaining four fastening screws and pull the transmission only far enough away from the engine to allow insertion of special tool locating pin 9595 1 for hol...

Page 812: ...ission all the way in and bolt it to the intermediate case 5 Insert a wooden support of special tool spacer 9111 4 between the transmission housing and transverse strut of special tool additional supp...

Page 813: ...er Installing ATF filter Tightening torques top of page Tools Item Special tool designation Remarks Connection hose 9507 1 top of page Removing ATF filter 1 Remove underbody panels rear and centre 2 R...

Page 814: ...at gasket on the suction collar of the new ATF filter with Vaseline and install filter 2 Clean ATF pan 3 Fit ATF pan with new seal Tighten the screws crosswise in several stages Tightening torque 8 Nm...

Page 815: ...read Tightening torque Nm ftlb Drain plug to ATF pan M 10 22 16 ATF pan to transmission M6 8 6 Transmission cross member to body M 10 65 48 996420 996421 996450 996451 996620 996621 996650 996651 eino...

Page 816: ...ctrohydraulic control unit Tightening torques top of page Tools Item Special tool designation Remarks A Assembly aid 9663 B Ratchet 1 4 inch Commercially available C Extension 1 4 inch Commercially av...

Page 817: ...oved or without ATF filling 1 Remove rear underside panel 2 Remove cross member 3 Disengage the coolant lines at the fastening points 4 Disengage cable at the retaining clips of the ATF pan einordnung...

Page 818: ...ion side 8 Remove the holders for the coolant hoses 9 Unlock the plug connection by turning it to the left and pull out the plug 10 Unscrew the fastening screw for the pilot bushing using special tool...

Page 819: ...talling the electrohydraulic control unit Install in reverse order observing the following points 1 Place selector lever in position P and place the control unit carefully in position The selector val...

Page 820: ...into the plug connection and lock by turning it to the right 7 Install the holder for water hoses It is essential that the centring pin engages in the holder bore Tighten the fastening screw Tightenin...

Page 821: ...0 65 48 Plug connection to socket M4 2 5 2 0 Drain plug to ATF pan M10 22 16 Control screw to ATF pan M10 22 16 ATF pan to transmission M6 8 6 Control unit to transmission M6 8 6 Water hose holder to...

Page 822: ...noid and control valve Installing solenoid and control valve Reassembling the hydraulic and electrical control unit top of page Tools Item Special tool designation Remarks Gripper Commercially availab...

Page 823: ...rect position 6 Solenoid valve 2 3 gearshift 1 Pull out with gripper 7 Control solenoid valve converter jumper 1 As No 6 8 Solenoid valve 1 2 and 4 5 1 As No 6 9 Solenoid valve 3 4 gearshift 1 As No 6...

Page 824: ...Unscrew screw 3 in overview remove leaf spring 5 in overview and pull out solenoid or control valve 6 to 11 in overview if necessary with a pair of pliers top of page Installing solenoid and control...

Page 825: ...t carefully in position The guide pin must engage in the guide bore of the hydraulic control unit 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Reassembling the hydraulic and elec...

Page 826: ...assembly and disassembly B Ball joint extractor track rod extractor commercially available refer to Workshop Equipment Manual Chapter 2 4 No 113 C Press out tool ball joint extractor 9560 To press ou...

Page 827: ...rack rod and control arm on wheel carrier 6 Press ball joint off control arm 1 with press out tool 9560 and ball joint off track rod 2 using a commercially available track rod extractor Note To preven...

Page 828: ...thread with Optimoly HT Taper of ball joints and wheel carrier must be free of grease When tightening the fastening nuts counter with Torx screwdriver 9546 1 Grease the toothing and the thread of the...

Page 829: ...fer to Workshop Equipment Manual Chapter 2 4 No 113 C Press out tool ball joint extractor 9560 To press out the ball joint on the wheel carrier top of page Removal 1 Open front lid and remove the resp...

Page 830: ...tion of the collar nuts on the spring strut mount and undo Note Cover the drive shaft for protection before removing the spring strut Drive shaft remains fitted on front axle final drive 10 Loosen cla...

Page 831: ...ust point in the direction of travel 3 Insert wheel carrier with spring strut into the vehicle 4 Check and adjust wheel alignment values at the front axle Note If assembly work was performed or parts...

Page 832: ...115 mm Commercially available see Workshop Equipment Manual Chapter 2 4 No 111 As a support when pressing out the rear wheel hub and the wheel bearing inner race of the wheel hub C Tubular piece VW 4...

Page 833: ...10 9 4 Tighten to 37 Nm 27 ftlb 3 Lid 1 Fit in correct position groove down 4 Wheel bearing 1 Heat wheel bearing housing to approx 100 C max 120 C Press out wheel bearing with tubular piece VW 415 A...

Page 834: ...ss appropriate shims will additionally be necessary 3 Remove retainer plate lid four screws 4 Heat wheel bearing housing to approx 100 C max 120 C Press out wheel bearing with tubular piece VW 415A to...

Page 835: ...ring and then press again slightly using pressure piece 9247 3 D and tubular piece VW 415 A C 3 Fit retainer plate lid Unless there is a water drain on both sides fit the water drain arrow in the corr...

Page 836: ...mount in the vehicle interior 5 Loosen stabilizer mount at stabilizer counter with open ended wrench 6 Loosen screw connection between spring strut wheel carrier arrow 7 Pull out remove spring strut...

Page 837: ...out Before tightening the fastening nuts adjust spring strut mount in accordance with the applied marking position of the three fastening nuts Insert spring strut into vehicle Tightening torque 46 Nm...

Page 838: ...Series wheel bolt Turbo and GT2 dimension X approx 45 mm B GT3 wheel bolt dimension X approx 50 mm Designation with GT or red color arrow top of page Removing installing the wheel on vehicle Turbo and...

Page 839: ...remove the 3 remaining wheel bolts and remove the wheel carefully without touching the brake discs Note The assembly pins can be ordered separately as a spare part Part No 999 571 074 30 2 Fasten the...

Page 840: ...e resulting from seizure of the bolt head bearing surface and spherical cap ring It must be possible to rotate the spherical cap ring on the bolt shank and to move it in the axial direction Note Alway...

Page 841: ...sed when installing the steel valve Fix disc into the correct position using the O ring and the fastening nut Only use the original valve cap top of page Notes on removal and installation Do not use c...

Page 842: ...rrectly the O ring will be damaged 4 Serious damage is possible as a result top of page Removal 1 Unscrew valve cap 2 Undo fastening nut 2 When undoing the fastening nut 2 counter with a screwdriver i...

Page 843: ...disc depression 3 Install the fastening nut 2 with the shaft facing towards the valve foot Tighten the fastening nut 2 with a torque wrench to 3 5 2 5 ftlbs 0 5 Nm 0 5 ftlb When tightening counter wi...

Page 844: ...nnot be adjusted There is no O ring between speed sensor and wheel carrier The speed sensors at front and rear axles are the same 1 Coat speed sensor and the bore in the wheel carrier with Molykote Lo...

Page 845: ...is determined by the design and cannot be adjusted There is no O ring between speed sensor and wheel carrier The speed sensors at front and rear axles are the same 1 Coat speed sensor and the bore in...

Page 846: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installation 783...

Page 847: ...new current version with part number 996 355 955 58 should be installed At the first installation of the new current hydraulic unit 996 355 955 58 instead of the first version 996 355 955 51 ensure t...

Page 848: ...ic unit D the booster pump A of the brake master cylinder B and the brake booster C remains fitted installed 1 Switch off ignition Remove cover A from the hydraulic unit brake unit 2 Hold down brake p...

Page 849: ...with brake fluid or water Any damp plug must be wiped dry before being disconnected from the plug on the hydraulic unit Brake fluid on electrical contacts even thinned brake fluid leads to corrosion...

Page 850: ...connections for leaks Read out and erase the fault memory of the PSM control module with the Porsche System Tester 2 PST 2 Additionally perform the static test in the PSM system Check electrical and...

Page 851: ...rsche Stability Management system in the 911 Turbo 996 since series intoduction of this vehicle The first version A with part number 996 606 147 00 and the new current version B with part number 996 6...

Page 852: ...st time installation various parts must be replaced in the surrounding area and some parts are omitted The conversion to the new current version is described in Repair Group 45 in the chapter Conversi...

Page 853: ...Never pull the electrical connections top of page Installation 1 Install in reverse order 2 After installing the rate of turn sensor read out the PSM fault memory with the Porsche System Tester 2 and...

Page 854: ...led for the PSM Porsche Stability Management system in the 911 Turbo 996 since the production launch of this vehicle The first version A with part number 996 606 147 00 and the new current version B w...

Page 855: ...ent rate of turn sensor can be retrofitted The following instructions describe the conversion top of page Overview of rate of turn sensor conversion In case of first time installation of the new curre...

Page 856: ...on Component SP No explanation PSM control module 996 618 149 01 Installed as standard Hydraulic unit 996 355 955 51 Installed as standard Rate of turn sensor Item 3 996 606 145 00 Adapter plug Item X...

Page 857: ...arger to start the engine Never pull off or push on the wiring harness plugs of the control modules or other electronic components when the ignition is switched on 1 Move the front seats into the rear...

Page 858: ...ter 3 upward out of the support bracket Disengage cable nipple 1 on the keylock lever 2 7 Unlock plug of the rate of turn sensor with the ignition switched off arrow on the plug and pull it off Undo f...

Page 859: ...sensor is a micro mechanical component and is very sensitive to impacts 1 Install new current holder B dimension X approx 60 mm 6 fastening screws Dimension X of the holder for the first version A is...

Page 860: ...ween the new rate of turn sensor and the existing plug 4 Install the adapter plug adapter lead with plugs and the rate of turn sensor To do this Connect the plug on the adapter lead X to the existing...

Page 861: ...console front part 8 Install side panel linings in front of the centre console 9 Connect battery ground cable 10 Code the radio and PCM 11 Carry out the following tests Read out and erase the fault m...

Page 862: ...e sensor Modified versions as of 2003 model Notes on replacing the steering angle sensor vehicles prior to 03 model D Cover top of page Notes on steering wheel position during removal and installation...

Page 863: ...B in the direction of travel A Universal joint of steering shaft B Cable guide C Steering angle sensor D Cover Note Pull at the plug housing only Never pull the electrical connections 6 Pull off stee...

Page 864: ...axial plug connection below steering shaft previous steering angle sensor C1 radial lateral plug connection When a replacement is required new steering angle sensor C2 can be retrofitted in place of t...

Page 865: ...the ribs in the old cable guide B1 Adapter lead E is inserted fitted between new steering angle sensor C2 and the existing previous lead X The leads that are joined together X and E are then inserted...

Page 866: ...damaged Observe mounting specifications Avoid uncontrolled twisting of steering wheel in the wheel position by turning the steering wheel when the universal joint is being removed on the steering shaf...

Page 867: ...gage adapter 1 to the steering shaft Stage 2 Fit steering angle sensor to adapter 1 detailed instructions on how to do this will follow 1 Hub adapter 2 Driver for steering angle sensor 3 Internal lock...

Page 868: ...fitted on the steering shaft the contact unit spiral spring may no longer be in the correct position If this is the case remove steering wheel and move contact unit to centre position 2 Secure steerin...

Page 869: ...plug connection into the cable slot and secure with a thin tie wrap arrow Before inserting the leads into the cable slot fold them so that the leads lie directly above one another and are correctly po...

Page 870: ...p carry out the following removal steps Remove suction line 2 for booster pump Undo pressure pipe on the booster pump 3 Close the lines and the pump connections with suitable plugs Release plug 4 arro...

Page 871: ...ooster pump the bleeding device should remain connected switched on Bleeding pressure approximately 2 0 bar 3 Carry out the following tests Read out and erase the fault memory of the PSM control modul...

Page 872: ...the pedal plate of the brake pedal Adjusting the pushrod length changes the position of the brake pedal Note Check adjustment of the brake light switch if brake pushrod is adjusted Undo the lock nut a...

Page 873: ...ation dampers each time the pads are changed The vibration dampers have an adhesive protective film The protective film must be pulled off before installation top of page Removal 1 Remove the retainer...

Page 874: ...to detach the vibration dampers from the brake pad backing plate before removing the pads top of page Installation WARNING Danger of accident if old parts are fitted on brake caliper Fit new expandin...

Page 875: ...al times to position the brake pads on the brake discs 8 Check and if necessary correct the brake fluid level Bedding in the brake pads New brake pads require a bedding in period of approx 200 km Not...

Page 876: ...ampers each time the pads are changed The damper plates have an adhesive protective film The protective film must be pulled off before installation top of page Removal 1 Remove the retainer safety bra...

Page 877: ...tula to detach the damper plates from the brake pad backing plate before removing the pads top of page Installation DANGER Danger of accident if old parts are fitted on brake caliper Fit new expanding...

Page 878: ...times to position the brake pads on the brake discs 8 Next check and if necessary correct the brake fluid level Bedding in the brake pads New brake pads require a bedding in period of approx 200 km N...

Page 879: ...expanding spring when fitting the dial gauge holder 1 Mount the adapter plate 9510 1 on the wheel hub Tightening torque of the wheel bolts fastening screws 130 Nm 96 ftlb 2 Insert dial gauge holder e...

Page 880: ...er to Workshop Equipment Manual Chapter 2 4 No 147 1 Wheel hub lateral runout is too large Replace the wheel hub Wheel hub lateral runout OK Clean the levelling and centring surfaces on the brake disc...

Page 881: ...suitable place in the wheel well do not open the brake hydraulics 7 Take off the brake disc after removing the countersunk screws top of page Installation Note Do not confuse right and left brake dis...

Page 882: ...e disc 5 Fit the brake caliper Replace the brake caliper fastening screws after each removal Tightening torque of the fastening screws 85 Nm 63 ftlb 996420 996421 996450 996451 996620 996621 996650 99...

Page 883: ...expanding spring when fitting the dial gauge holder 1 Mount the adapter plate 9510 1 on the wheel hub Tightening torque of the wheel bolts fastening screws 130 Nm 96 ftlb 2 Insert dial gauge holder e...

Page 884: ...er to Workshop Equipment Manual Chapter 2 4 No 147 1 Wheel hub lateral runout is too large Replace the wheel hub Wheel hub lateral runout OK Clean the levelling and centring surfaces on the brake disc...

Page 885: ...emoving the countersunk screws arrows If a stuck brake disc cannot be removed by gentle tapping with a plastic hammer evenly screw hexagon head bolts into the two M8 threads of the brake disc thereby...

Page 886: ...06 00 3 Adjust the parking brake shoes and parking brake cables 4 Fit the brake caliper Replace the brake caliper fastening screws after each removal Tightening torque of the fastening screws 85 Nm 63...

Page 887: ...king effect being apparent Note The parking brake has asbestos free brake linings The parking brake with asbestos free brake linings must never be adjusted in such a way that the lining must grind dow...

Page 888: ...release approx 3 notches until the brake disc can be moved freely then release another 2 notches 6 Repeat the procedure on the other wheel 7 Pull up the parking brake lever by 2 teeth and adjust the a...

Page 889: ...res on the brake caliper holder and the brake pad wear wire on the wheel carrier holder 4 Take off the brake disc after removing the countersunk screws If a stuck brake disc cannot be removed by gentl...

Page 890: ...eading lever are positioned correctly and adjust if necessary Note Ensure that the hooks of the compression springs No 10 correctly clasp the wheel carrier A if necessary check with the aid of a mirro...

Page 891: ...parking brake cables Fit the brake caliper Tightening torque of the fastening screws 85 Nm 63 ftlb Ensure that the brake hose and brake line are in perfect position Note Replace the brake caliper fas...

Page 892: ...the following part numbers Quantity supplied 1 litre 000 043 203 66 Quantity supplied 30 litre 000 043 203 67 top of page Procedure for bleeding 1 Bleed brakes as usual 2 Then bleed at front on right...

Page 893: ...fully depress the brake pedal several times Hold for 2 3 seconds after each depression then release slowly Repeat this procedure in the sequence rear left front right front left This will remove all...

Page 894: ...time has elapsed the Tester switches off automatically leaves the menu If necessary continue the procedure after a certain waiting time select Bleed menu again 4 Press the Start button on the System...

Page 895: ...e fluid 2 Connect a bleeding device to the brake fluid reservoir 3 Switch on the bleeding device Bleeding pressure approximately 2 0 bar Note Drain brake fluid on every brake caliper on both bleeder v...

Page 896: ...tch off and disconnect the bleeding device Correct the brake fluid level if necessary 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Procedure for changing brake flui...

Page 897: ...ed installed during removal and installation of the brake master cylinder 1 Remove cover A from the hydraulic unit brake unit 2 Remove brake fluid from reservoir using suction 3 Disconnect the electri...

Page 898: ...lation 1 Install in reverse order 2 Bleed the brakes Bleeding brakes vehicle with PSM Note First bleed brakes as usual Do not carry out booster pump activation with the Porsche System Tester 2 until a...

Page 899: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installation 836...

Page 900: ...n if both parts should continue to be used 1 Switch off ignition Remove cover A and B 2 Drain brake fluid explansion tank To do so suck brake fluid out of the expansion tank or pump out the brake flui...

Page 901: ...aulic connections the electrical plug connections on the hydraulic unit must always be connected This prevents the plug connections on the hydraulic unit or in the plugs inside from being splashed wit...

Page 902: ...he brake booster Torx T 45 Pull out brake booster top of page Installation When replacing the brake booster observe the correct allocation according to the Spare Parts catalogue Different transmission...

Page 903: ...ry correct during the relevant work 2 Insert brake booster with bellows B and tightened clamps 6 Note Do not trap wiring harness 3 Tighten fastening screws Torx T 45 arrow to 23 Nm 17 ftlb 4 Connect t...

Page 904: ...ck nut for this purpose and the turn the push rod accordingly at the hexagon arrow until dimension X 45 5 mm has been achieved Subsequently re tighten the the lock nut 6 Fit the bellows onto the body...

Page 905: ...nual transmission or Tiptronic 12 Carry out the following tests Check the system brake lines and connections for leaks Read out and erase the fault memory of the ABS or PSM control module with the Por...

Page 906: ...13 Install covers A B 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installation 843...

Page 907: ...ering wheel is pulled back Likewise the contact unit unlocks automatically when the steering wheel is refitted 1 Disconnect the battery and cover terminal or battery 2 Remove driver s airbag unit For...

Page 908: ...ad position or after disassembly with the marking so that the upper spokes of the steering wheel are horizontal 2 Fit hexagon nut arrow with spring washer and tighten to 45 Nm 33 ftlb 3 Install driver...

Page 909: ...will have to be put in centre position after installation of the stearing gear 2 Loosen universal joint steering shaft arrow at steering gear Take out the clamping screw and slide the joint upwards 3...

Page 910: ...ng gear Track rod on steering gear top of page Installation Install in reverse order It is essential to observe the following points while doing so Replace steering gear fastening screws and the fit b...

Page 911: ...leed steering system Tighten all screw connections with the prescribed tightening torque values Check and or adjust track Notes for sliding piece and airbag contact unit 1 If sliding piece No 1 was pu...

Page 912: ...rows No 1 1 Drivers that engage in the steering wheel 2 Locking securing against turning which becomes effective after removal of the steering wheel 3 5 Turn front wheels to straight ahead position be...

Page 913: ...50 55 19 Removing and installing the wing 50 55 19 Removing and installing the wing 850...

Page 914: ...iners front Removing and installing filler flap 941419 Removing and installing headlight mount 941519 Removing and installing headlights For the right wing 202519 Removing and installing carbon canist...

Page 915: ...eetmetal screw St 6 3 x 12 4 15 Sheetmetal nut 11 16 Wing 1 Pull out downwards at the A pillar and remove to the front Insert the wing under the lid hinge at the front fit the sheetmetal screws Adjust...

Page 916: ...22 Sheetmetal screw B 4 2 x 18 2 23 Servo motor 1 996420 996421 996450 996451 996430 996431 996840 996841 einordnung 50 55 19 Removing and installing the wing 853...

Page 917: ...50 56 19 Removing and installing wheel housing liners front 50 56 19 Removing and installing wheel housing liners front 854...

Page 918: ...1 3 Sheetmetal nut B4 8 12 Adjust to centre of hole 4 Expanding rivet St 6 3 1 Check replace if necessary 5 Combination screw B4 8 x 16 6 Plastic nut T5 22 x 10 Check replace if necessary 996420 99642...

Page 919: ...53 69 19 Removing and installing wheel housing liners rear 53 69 19 Removing and installing wheel housing liners rear 856...

Page 920: ...downwards 2 Rear left wheel housing liner rear 1 Pull out downwards 3 Sheetmetal screw 3 7 Undo 4 Plastic nut T5 5 Undo Inspect and replace if necessary 5 Sheetmetal nut 2 996420 996421 996450 996451...

Page 921: ...or front lid Disassembling release for front cover Assembling release for front cover Removing and installing support for cap release top of page Disassembling release for front cover 55 10 37 Disasse...

Page 922: ...lastic spatula and press out Check fastening clips 4 replace if necessary 3 Pulling off plug connections 5 6 of the actuating switches Pull off plug connections 5 6 on the actuating switches of the li...

Page 923: ...tions 5 6 of the actuating switches Push plug connections 5 6 onto the actuating switches of the lids 3 Attaching sill 1 Clip in new fastening clips 4 if necessary Insert sill 1 downward into the lowe...

Page 924: ...for cap release 1 Preassembled dowel pin 3 is pressed in with the support 2 into the body 3 Locating pin 1 Pull out the pin Press in the pin 4 Felt support 1 Pull off Check if necessary replace 5 Pla...

Page 925: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung Removing and installing support for cap release 862...

Page 926: ...55 17 19 Removing and installing front lower part of lid lock Removing and installing bowden cable for lock actuation 55 17 19 Removing and installing front lower part of lid lock 863...

Page 927: ...rrow B 2 Electrical plug connection 1 At arrow C press and disconnect Plug in the electrical plug connection 3 Hexagon head bolt 2 Undo Screw in Tightening torque 10 Nm 7 5 ftlb 4 Cover panel 1 Separa...

Page 928: ...owden cable 7 into the lower part of the lid lock 8 Bowden cable emergency release USA and Canada vehicles only 1 Turn bowden cable 8 in the direction of the arrow and remove from the servo motor 9 In...

Page 929: ...nect 4 Guide for bowden cable 1 Pull off Push on 5 1 Bowden cable 1 Disengage nipple of bowden cable 5 1 and press the cover out of the lower part of the lid lock Pull the rubber sleeve arrow A out of...

Page 930: ...bowden cable 5 2 out of the stamp of the servo motor Insert bowden cable 5 2 into the stamp of the servo motor 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Removing and installin...

Page 931: ...55 22 19 Removing and installing front lid 55 22 19 Removing and installing front lid 868...

Page 932: ...5 ftlb 2 Lid 1 Undo combination screws 1 from the hinge and remove lid 2 Position lid 2 on the left and right hinges and adjust according to the lid contour to the left side section 996420 996421 9964...

Page 933: ...55 22 37 Disassembling and assembling front lid 55 22 37 Disassembling and assembling front lid 870...

Page 934: ...2 Screw in rubber pads 2 3 Self adhesive label tyre pressure 1 4 Combination screw M6 x 12 2 Tightening torque 10 Nm 7 5 ftlb 5 Upper part of lock Take upper part of lock 5 off lid 1 Fasten upper par...

Page 935: ...ge on lid Remove base 8 of lid badge 7 Insert base 8 and lid badge 7 into the lid and fasten with tapping nut 6 8 Base 1 996420 996421 996450 996451 996430 996431 996840 996841 einordnung 55 22 37 Dis...

Page 936: ...55 25 19 Removing and installing front lid hinge 55 25 19 Removing and installing front lid hinge 873...

Page 937: ...4 3 Combination screw M6 x 14 4 Undo fastening screws 3 from the hinge 4 Position hinge 4 on the body and screw in place with the fastening screws 3 Tightening torque 10 Nm 7 5 ftlb 4 Hinge 1 996420...

Page 938: ...55 37 19 Removing and installing filler flap 55 37 19 Removing and installing filler flap 875...

Page 939: ...ller flap on the wing cut out and press in until the fastening lugs engage 2 Plastic hinge 1 Insert the disassembly tool at the locking lugs on the left and right and lift via the locking lugs push th...

Page 940: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung 55 37 19 Removing and installing filler flap 877...

Page 941: ...ling and assembling release for rear lid Disassembling release for rear lid Assembling release for rear lid top of page Disassembling release for rear lid 55 57 37 Disassembling and assembling release...

Page 942: ...plastic spatula and press out Check fastening clips 4 replace if necessary 3 Pulling off plug connections 5 6 of the actuating switches Pull off plug connections 5 6 on the actuating switches of the...

Page 943: ...5 6 of the actuating switches Push plug connections 5 6 onto the actuating switches of the lids 3 Putting on sill cover 1 Clip in new fastening clips 4 if necessary Insert sill 1 downward into the lo...

Page 944: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung Assembling release for rear lid 881...

Page 945: ...55 86 19 Removing and installing lower part of lid lock 55 86 19 Removing and installing lower part of lid lock 882...

Page 946: ...vo motor unit 1 4 Retaining clip 1 Press out Press in 5 Emergency release cable 1 6 Electrical plug connection 1 Interior lighting plug connection Press lug arrow and separate 7 Electrical plug connec...

Page 947: ...7 996420 996421 996450 996451 996430 996431 996840 996841 einordnung 55 86 19 Removing and installing lower part of lid lock 884...

Page 948: ...55 90 19 Removing and installing rear lid 55 90 19 Removing and installing rear lid 885...

Page 949: ...ion 1 and separate Connect electrical plug connection 1 2 Hexagon head bolt M6 x 16 4 Undo Tightening torque 10 Nm 7 5 ftlb 3 Rear lid 1 Adjust lid 3 to the hinges in accordance with the contours of t...

Page 950: ...55 90 37 Disassembling and assembling rear lid Disassembling rear lid Assembling rear lid Replacing the model logo top of page Disassembling rear lid 55 90 37 Disassembling and assembling rear lid 887...

Page 951: ...tended Do not smoke during work avoid open flames Danger of fire Do not swallow hydraulic oil avoid contact with skin eyes Rinse with water in the case of contact with skin eyes Open banjo bolts very...

Page 952: ...sides unlock lock B Remove brake light and disconnect plug connection C 3 Pull off rubber cover 4 4 Remove adjusting element Unscrew rubber pad 5 and disengage collar 6 5 Remove upper part of lock 8...

Page 953: ...lements 15l and 15r Pull mount 13 gently forwards and unscrew the fastening screws 16 of the pump unit 17 Remove mount 13 Unscrew the fastening screws 14 of the extension elements 15l and 15r Remove p...

Page 954: ...d on the right hand side Hose connections must both point in the direction of the centre and the rear edge of the lid arrows Screw in fastening screws 14 of the extension elements 15l and 15r and tigh...

Page 955: ...ds 5 8 Install rubber cover 4 9 Install additional brake light 3 Push on plug C Insert brake light Lock the lock B Engage cover A Install rear lid Removing and installing rear lid 10 Install spoiler 6...

Page 956: ...ews arrows to 10 Nm 7 5 ftlb Stick on model logo Replacing the model logo top of page Replacing the model logo 1 Position logo with the dimensions X 332 mm and Y 20 mm on the rear lid and affix 996420...

Page 957: ...55 91 19 Removing and installing lid hinge 55 91 19 Removing and installing lid hinge 894...

Page 958: ...e sides 2 Fuse 4 Press out with a narrow screwdriver Press in 3 Pneumatic spring left right 2 4 Stop clip left right 2 5 Combination screw M6 x 16 4 Tightening torque 10 Nm 7 5 ftlb 6 Lid hinge right...

Page 959: ...d hinge left 1 Undo combination screws 5 Adjust to the left side section in accordance with lid contour 996420 996421 996450 996451 996840 996841 einordnung 55 91 19 Removing and installing lid hinge...

Page 960: ...57 11 37 Disassembling and assembling door handle 57 11 37 Disassembling and assembling door handle 897...

Page 961: ...of the connection piece the bottom part of the door handle and the door lock the fuse No 1 in row D must be removed No Designation Qty Removal Installation 1 M 6 collar nut 2 Undo 2 Connection piece 1...

Page 962: ...6 9 S retainer 1 10 Pin rod 1 Replace 11 Eccentric 1 12 Return spring 1 13 Handle 1 Pull pin rod 10 out of the handle liner 3 and separate handle from the handle liner Position return spring 12 eccent...

Page 963: ...57 37 19 Removing and installing inner door release bowden cable for door lock 57 37 19 Removing and installing inner door release bowden cable for door lock 900...

Page 964: ...Removing and installing door trim panel 2 Bowden cable 1 Door handle side Press the lugs of the plastic clip A and extend to the rear Push bowden cable back into the end piece of the sleeve B Door ha...

Page 965: ...the actuating lever B handle 2 Lock side Inset Y Insert the bowden cable in the actuating lever B and rotate by 90 A Clip bowden cable into the door lock C 996420 996421 996450 996451 996430 996431 99...

Page 966: ...57 45 19 Removing and installing door handle Removing and installing orientation lighting LED light emitting diodes 57 45 19 Removing and installing door handle 903...

Page 967: ...5 and the door trim panel 1 3 Sleeve 1 Pull off from the return spring 2 Put onto the return spring 2 4 Oval head screw 4 2 x 13 4 5 Door handle 5 1 Undo oval head screws 4 and pull the door handle o...

Page 968: ...ght emitting diode housing 2 Pull light emitting diode housing 2 to the rear out of the locks on the cover 3 Pull cover at front out of the door handle 2 Remove light emitting diode housing 1 Raise th...

Page 969: ...unit into the door handle from the rear 2 Install light emitting diode housing 1 Insert the light emitting diode housing 1 into the guide of the door handle until the lug arrow engages 3 Install ligh...

Page 970: ...the front until there is no more play on the lock of the light emitting diode housing 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Installing orientation lighting LED light emit...

Page 971: ...g of the characteristics has been completed after this process Note The lift button must not be released during the entire process In the event of a restart the lifting sliding roof must always be mov...

Page 972: ...he openings provided Undo fastening screws with a crosshead screwdriver arrow A 2 Unclip cover at the rear left and right arrow B push forward towards the windscreen and remove 3 Unscrew both fastenin...

Page 973: ...ing sliding roof drive after they have been loosened microencapsulated 2 Position lifting sliding roof drive in the teeth of the frame for the sliding roof and fasten with the Torx fastening screws ar...

Page 974: ...emergency operation An angle screwdriver a f 4 hexagon socket is clipped in behind the cover The drive axle can be turned with the angle screwdriver see figure The lifting sliding roof drive must not...

Page 975: ...ving and installing frame for sliding roof Removing frame for sliding roof Installing frame for sliding roof top of page Removing frame for sliding roof 60 28 19 Removing and installing frame for slid...

Page 976: ...ng roof frame have been omitted The new sliding roof frame can also be used in vehicles with a production date before 01 01 2001 if the separately available holders are prefitted at the side of the fr...

Page 977: ...e sliding roof frame 4a Unscrew the fastening screws B C at the side vehicles without roof frame reinforcement in the body structure Unscrew the fastening screw from the sliding roof frame at the side...

Page 978: ...r sliding roof into the vehicle Insert sliding roof frame with an assistant into the passenger compartment through the door aperture and position at the screw mounting points 1a Screw in the fastening...

Page 979: ...ening screws with the correct tightening torque Tighten all fastening screws according to the following table 3 Connecting electrical plug connection Plug in the electrical plug connection The locking...

Page 980: ...and assembling frame for sliding roof Disassembling frame for sliding roof Assembling frame for sliding roof top of page Disassembling frame for sliding roof 60 28 37 Disassembling and assembling fram...

Page 981: ...of frame Lifting sliding roof drive draught deflector frame clips No Procedure Instructions 1 Removing draught deflector Fold the draught deflector up press it inwards and out of the guides at the lef...

Page 982: ...until the left and right tabs engage 2 Fitting lifting sliding roof drive Position lifting sliding roof drive into the teeth of the frame Screw in with the Torx T25 fastening screws and tighten Tight...

Page 983: ...ress the draught deflector in on the left and right and insert it into the guides at the sides Fold up the draught deflector 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Assembli...

Page 984: ...9 Removing and installing sliding roof panel Additional instructions for removing the inner panels Additional instructions for fitting the inner panels 60 40 19 Removing and installing sliding roof pa...

Page 985: ...roof Item 4 must be shifted without the use of force No Procedure Instructions 1 Open sliding roof panel Open the sliding roof panel approx 80 mm 2 Disengage sliding tilting roof trim Disengage press...

Page 986: ...crews T25 from the sliding roof panel and remove the panel from the sliding roof frame Note The sliding roof panel may be installed in the sliding roof frame only in zero position No Procedure Instruc...

Page 987: ...edge cut out While doing so take care not to push trim of sliding tilting roof upwards This could detach or damage the inner panels 6 Open sliding roof panel Open sliding roof panel approx 80 mm Pull...

Page 988: ...the sliding roof frame inwards centre of the vehicle top of page Additional instructions for fitting the inner panels Installing inner panels Press the sides of the inner panel into the sliding roof f...

Page 989: ...oof edge cut out Engage the left and right hand inner side panels in the sliding tilting roof trim Repeat the procedure for installing the sliding roof panel 996420 996421 996450 996451 996430 996431...

Page 990: ...63 10 19 Removing and installing front bumper Removing and installing front bumper top of page Removing and installing front bumper 63 10 19 Removing and installing front bumper 927...

Page 991: ...Nm 7 5 ftlb 3 Left and right retaining strip 1 Undo the collar nut 1 and sheetmetal screw 4 out of the retaining strip Position retaining strip on the wing upward so that the clearance rib rests again...

Page 992: ...on screw M8 x 30 4 Undo Tightening torque 23 Nm 17 ftlb 11 Impact pipe 2 Undo combination screw 10 and remove impact pipe and seal Fix the impact pipe to the body with the seal and fasten with the com...

Page 993: ...63 15 19 Removing and installing front spoiler Removing front spoiler Installing front spoiler top of page Removing front spoiler 63 15 19 Removing and installing front spoiler 930...

Page 994: ...from the front part 1 2 Remove direction indicator light Press in spring clip of direction indicator light arrow A at the sides with a screwdriver and take out the direction indicator light 5 disconn...

Page 995: ...the underbody Remove front spoiler 1 to the front top of page Installing front spoiler No Procedure Instructions 1 Fit front spoiler 1 Lift the front spoiler 1 near the headlights above the radiators...

Page 996: ...cover Fasten the front end 1 with the sheetmetal screws 4 Affix cover 3 turn hexagon cap nuts 2 by 45 5 Fit direction indicator light Connect electrical plug connection of the direction indicator lig...

Page 997: ...63 15 37 Disassembling and assembling front spoiler Disassembling front spoiler Assembling front spoiler 63 15 37 Disassembling and assembling front spoiler 934...

Page 998: ...ff protective film 3 2 Remove covering frame 4 Press in the lugs of the covering frame 4 and lift it up and off carefully 3 Remove frame centre 5 Carefully disengage the lugs of the frame centre 5 on...

Page 999: ...the grille frame 7A on all sides using a screwdriver Remove hexagon head bolt 10A and the hexagon socket head bolts 8A from the spacer 9A remove impact horn 12A Note the retaining bracket 11A must be...

Page 1000: ...crews 3 from the front spoiler 1 at the sides 2 Remove sheetmetal frame 2 Pull sheetmetal frame 2 out of the lower rib of the front spoiler 1 3 Remove front spoiler 1 Press in the lugs with a screwdri...

Page 1001: ...exagon socket head bolts 8A screw the impact horn 12A through the retaining bracket 11A Lock grille frame 7A on all sides 2 Install grille frame 7 Lock grille frame 7 on all sides in the front end 1 P...

Page 1002: ...front spoiler 1 Insert the front spoiler 1 into the groove of the front end Make sure that all lugs are engaged 2 Tighten front spoiler 1 Use the fastening screws 3 and spacer sleeve 4 to tighten the...

Page 1003: ...996420 996421 996450 996451 einordnung Installing front spoiler 940...

Page 1004: ...r Installing rear bumper Additional assembly instructions for installation of the bumper Additional assembly instructions for installation of the bumper Carrera 4S Tightening torques top of page Remov...

Page 1005: ...ff collar nuts 6 and remove centre retaining strip 5 Check sheetmetal nuts 7 replace if necessary 3 Remove and disassemble rear bumper 8 or 8A USA version Unscrew sheetmetal screws 11 and fastening sc...

Page 1006: ...e sides 23 Note In order to remove the heat shield at the sides 23 the charge air cooler or the exhaust system must be removed 214319 Removing and installing the air charge cooler 260119 Removing and...

Page 1007: ...nium layers tears and missing or damaged sealing strips After assembling the bumper check the heat shields for leaks No Procedure Instructions 1 Install centre heat shield on top 18 Screw on centre he...

Page 1008: ...ining strip 5 with sheetmetal nuts attached 7 and screw on with collar nuts 6 Note observe adjsuting dimension Additional assembly instructions for installation of the bumper Additional assembly instr...

Page 1009: ...cked in the lock in accordance with the joining plan before the rear bumper or centre retaining strip are assembled Note All measurements refer to the position V 260 mm 1 Adjust the rear lid according...

Page 1010: ...without gaps The following minimum gap dimensions must be observed Note All measurements refer to the position V 260 mm Measuring axis for dimension W in the extension of the lower retaining strip 1...

Page 1011: ...sealing area must be sealed off without gaps The following minimum gap dimensions must be observed Note All measurements refer to the position V 260 mm Measuring axis for dimension W in the extension...

Page 1012: ...thout gaps Tighten the collar nuts 1 and fastening screw 11 top of page Tightening torques Location Illustration Thread Tightening torque Fastening screws of impact pipe on body 21 M8 23 Nm 17 ftlb Fa...

Page 1013: ...63 55 19 Removing and installing rear spoiler Removing rear spoiler Install rear spoiler top of page Removing rear spoiler 63 55 19 Removing and installing rear spoiler 950...

Page 1014: ...ws 3A and remove impact horn 2A Note the fastening screws 3A can remain on the bumper with the washers 2A 2 Remove cover moulding 6 and sheetmetal screws 7 Unscrew sheetmetal screws 5 and sheetmetal s...

Page 1015: ...distorted heat shields must be straightened or replaced Check heat shields for deformation bonding detachment of the aluminium layers tears and missing or damaged sealing strips After assembling the r...

Page 1016: ...sheetmetal screws 5 and sheetmetal screws 7 4 Screw in sheetmetal screws 8 Fasten rear spoiler with sheetmetal screws 8 5 Fit impact horns only USA version 2A Put on impact horn 2A align at the sides...

Page 1017: ...d assembling rear spoiler Disassembling rear spoiler Assembling rear spoiler Additional instructions for replacing the rear spoiler top of page Disassembling rear spoiler 63 55 37 Disassembling and as...

Page 1018: ...w retaining clips 18 for installation No Procedure Instructions Removing rear spoiler Removing rear spoiler 1 Remove shield cover 1 Press off clamping washers 4 with a suitable tool remove shield 3 an...

Page 1019: ...r 13 and housing 14 Remove licence plate light with wiring harness 15 Unclip body bound rivets for licence plate holder 16 6 Remove air outlet grille 17 Move retaining clips 18 as far as possible to o...

Page 1020: ...Affix new wiring harness retainer 19 Press on firmly and briefly when affixing Put on licence plate light with wiring harness 15 housing 14 and cover 13 and fasten licence plate light by screwing in...

Page 1021: ...ge Additional instructions for replacing the rear spoiler Note Additional cut outs must be made for the impact horns USA version in the rear spoiler before the new component is painted For the ParkAss...

Page 1022: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung Additional instructions for replacing the rear spoiler 959...

Page 1023: ...res in the rear window do not warm up The tip of the sensor is used to measure from the outside on the centre of the rear window Note The heating wire on the rear window must run exactly under the tip...

Page 1024: ...indow Preparing the window section for installation Installing rear window Overview of tools and materials top of page Removing rear window WARNING Danger of cut injuries when removing and installing...

Page 1025: ...installing trim of A B and C pillars 2 Removing rear wall lining 3 Removing rear window wiper Fold up the cap unscrew the fastening nut lift and detach the spring washer and wiper arm 4 Disconnecting...

Page 1026: ...surrounding section is removed from the rear window undamaged it can be re used top of page Preparing the window section for installation 1 Removing adhesive from the body When removing remaining adh...

Page 1027: ...o cleaning solution residues may remain on the body top of page Installing rear window CAUTION Danger of material damage if specified curing time of adhesive is not observed The vehicle must not be us...

Page 1028: ...sed 2 Preparing 2 component bonding material for processing Processing of Porsche 2 component window bonding agents Note The bonding material has an open time of 15 min which means that the bonding ma...

Page 1029: ...Apply suction cups B to the rear window and insert the rear window into the window aperture 5 Aligning rear window Align the rear window in the Z and Y directions 6 Cleaning fields of vision Adhesive...

Page 1030: ...p of page Overview of tools and materials The following tools and materials are required for removal and installation of the rear window with 2 component adhesive Item Designation Source Remarks A Dou...

Page 1031: ...nation H1 Cleaning solution H5 Cartridge component A H2 Primer H6 Cartridge component B H3 Activator H7 Mixing nozzle H4 Swab H8 Processing nozzle Item Designation Source Remarks A Glass separating to...

Page 1032: ...66 13 19 Removing and installing air inlet Removing air inlet Installing air inlet top of page Removing air inlet 66 13 19 Removing and installing air inlet 969...

Page 1033: ...duct 2 Remove retaining clips 3 Unscrew sheetmetal screws 2 and pull off retaining clips 3 If necessary the tabs on the clips must be bent upwards using a screwdriver beforehand The retaining clips m...

Page 1034: ...nly in the lug bores Screw in sheetmetal screws 2 3 Install air inlet 1 Check lugs arrows on the air inlet 1 for damage replace air inlet if necessary Insert air inlet 1 in the air duct and engage eve...

Page 1035: ...996420 996421 996450 996451 996840 996841 einordnung Installing air inlet 972...

Page 1036: ...66 36 19 Removing and installing roof joint strip Removing roof joint strip Installing roof joint strip top of page Removing roof joint strip 66 36 19 Removing and installing roof joint strip 973...

Page 1037: ...iver outward until the roof joint clip disengages 4 Unclip fold out element 4 Insert a screwdriver beneath both ends of the fold out element 4 and lever out 5 Detach spreader 5 Insert a plastic spatul...

Page 1038: ...alling roof joint strip No Procedure Instructions 1 Fit base plate of Roof Transport System 11 The contact surface of the base plate must be free from dirt and grease Position the base plate of the Ro...

Page 1039: ...in the roof channel 5 Fit roof joint seal Push the roof joint seal onto the roof joint strip 2 all the way round 6 Clip in fold out elements 4 Position the fold out element 4 in the cut out of the roo...

Page 1040: ...66 58 19 Removing and installing rear spoiler Removing rear spoiler Installing rear spoiler top of page Removing rear spoiler 66 58 19 Removing and installing rear spoiler 977...

Page 1041: ...of malfunctions in the drive module lift the spoiler manually and support with support pads CAUTION Damage will result if emergency release of the drive module is carried out incorrectly Always make...

Page 1042: ...support pad The support pads should only be pushed in to the positions shown in the figure 3 Position outer tubes of the extension elements Align the bore on the outer tube of the extension element a...

Page 1043: ...her 90 until the lock locks Lock spoiler on both sides 3 Cover bore of closure peg Cover off bore of closure peg 4 by gently turning the outer tube 3 Note the outer tube 3 should be turned in an anti...

Page 1044: ...996420 996421 996450 996451 einordnung Installing rear spoiler 981...

Page 1045: ...he heating wires in the mirror glass do not warm up top of page Check with the temperature probe The tip of the sensor is used to measure from the outside on the centre of the mirror glass Note After...

Page 1046: ...6 89 19 Removing and installing rearview mirror Removing the rearview mirror Installing the rearview mirror top of page Removing the rearview mirror 66 89 19 Removing and installing rearview mirror 98...

Page 1047: ...rows of the plug connection 2 and pull the plug out 3 Disconnect the plug connection of the mirror housing 5 Disconnect the plug connection of the mirror housing 5 4 Remove mirror housing 8 Pull off s...

Page 1048: ...of the mirror housing 4 Stick on seal 4 Check sealing grommet 11 and replace if necessary connect the plug connection of the mirror housing 5 Position the sealing grommet 11 in the mirror triangle 3...

Page 1049: ...996420 996421 996450 996451 996840 996841 996430 996431 einordnung Installing the rearview mirror 986...

Page 1050: ...68 17 37 Disassembling and assembling centre console Disassembling and assembling cover for the oddments tray 68 17 37 Disassembling and assembling centre console 987...

Page 1051: ...arrel 1 Press in the locking tabs in inset C and guide the lock barrel 6 upwards out of the lock support 5 Press the lock barrel 6 in to the lock support 5 until the latter engages in the locking tabs...

Page 1052: ...guide out of the centre console towards the rear Position the extension bracket 13 on the centre console and secure with the fastening screws 12 top of page Disassembling and assembling cover for the...

Page 1053: ...ments tray cover 6 together on the centre console Press the hinge pin 5 into place 6 Lower section of oddments tray cover 1 7 Spring 1 8 Limiting band 1 Unclip the limiting band 8 from the centre cons...

Page 1054: ...68 23 19 Removing and installing sun visors Removing sun visors Installing sun visors top of page Removing sun visors 68 23 19 Removing and installing sun visors 991...

Page 1055: ...ut of the mounting saddle towards the centre of the car top of page Installing sun visors 2 Fit sun visor Insert the sun visor in the mounting saddle and push into the thrust bearing 996420 996421 996...

Page 1056: ...68 23 37 Disassembling and assembling sun visor Disassembling sun visor Assembling sun visor top of page Disassembling sun visor 68 23 37 Disassembling and assembling sun visor 993...

Page 1057: ...3 Remove bulb 5 and contact clips 4 Remove the Sofitte 12V 3W bulb 5 from the contact clip 4 Take the contact clips upwards out of the holder 4 Unclip mirror housing 2 Insert a narrow plastic spatula...

Page 1058: ...rners until it locks into place 3 Insert contact clips 4 and bulb 5 Position the contact clips 4 in the mirror housing and fit under the lug Insert Sofitte 12V 3W bulb 5 4 Position mirror insert 3 Pos...

Page 1059: ...996420 996421 996450 996451 996840 996841 996430 996431 einordnung Assembling sun visor 996...

Page 1060: ...e required to bond on the complete interior mirror A Cleaning solution 000 043 157 00 B Primer 000 043 158 00 C Cover film 000 043 177 01 D Activator 000 043 052 00 E Adhesive 000 043 051 00 Porsche p...

Page 1061: ...e press on duration of 40 50 seconds The bonding strength is 60 after one hour 100 bonding strength is reached after 24 hours of curing time No Procedure Instructions 1 Mark the position of the interi...

Page 1062: ...windscreen Mask the bonding area on the windscreen with primer template cover film C The marking for the position of the interior mirror must be visible in the center of the primer template 4 Prime th...

Page 1063: ...ling the interior rearview mirror Removing the interior rearview mirror Installing the interior rearview mirror top of page Removing the interior rearview mirror 68 27 19 Removing and installing the i...

Page 1064: ...rror base and secure to the mirror base Turn the rearview mirror through 90 at the mirror base using the pliers 9578 No 9578 2 2 Workshop Manual Release the pliers from the mirror base 2 Remove the mi...

Page 1065: ...mirror has been removed from its base as it otherwise cannot be ensured that the mirror will be seated securely when fitted If the mirror is being fitted for the second or third time inspect locking...

Page 1066: ...ecure the mirror Secure the pliers 9578 No 9578 2 2 Workshop Manual with the projecting plastic parts to the windscreen on the mirror base Turn the mirror base through 90 while simultaneously pressing...

Page 1067: ...nnection and detachment of the plug connection during work on the airbag system at least 1 minute The ignition unit is located above the centre console 1 Remove ignition key 2 Disconnect the battery a...

Page 1068: ...ly bright Use a 1 4 inch Allen key to tighten the shear off nuts A new triggering unit must be locked after it has been installed Tightening torque of the M6 hexagon nut 10 Nm 7 5 ftlb 996420 996421 9...

Page 1069: ...nit 4 Pull forward and disconnect the electrical plug connections 5 Remove the contact unit Note To prevent unintended rotation of the contact unit KE when the steering wheel has been removed the cont...

Page 1070: ...2 Ensure that the exact centre position arrows of the contact unit is maintained 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Installing contact unit 1007...

Page 1071: ...bag unit 3 screws in the steering wheel 4 Disconnect the electrical plug connection WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units Please observe the...

Page 1072: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung Installing driver s airbag unit 1009...

Page 1073: ...ted so that the airbag opening faces upwards If removed for an extended period the airbag unit must be kept in a locked place Observe the safety regulations 1 Remove ignition key 2 Disconnect the batt...

Page 1074: ...ling passenger s airbag unit Tightening torque for fastening screws 2 screws M8 x 95 20 Nm 15 ftlb 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Installing passenger s airbag unit...

Page 1075: ...ed period stored under dry conditions in a locked room Observe the safety regulations 1 Remove ignition key 2 Disconnect the battery and cover terminal or battery 3 Remove door trim panel 705937 Disas...

Page 1076: ...behind the side airbag unit must not be damaged protects against water leaking in 1 Install airbag unit with the inscription R in the right hand door and fasten 2 Engage electrical plug connection Ti...

Page 1077: ...riggered for the third time Note Sensors for triggering the side airbag unit are fastened on the inner lower side member on the left and right hand sides in the vehicle The cover strip and the support...

Page 1078: ...Removing and installing the instrument panel Removing and installing the instrument panel bracket Tightening torque Tools and materials top of page Removing and installing the instrument panel 70 18...

Page 1079: ...l 4 Screw the instrument panel 4 to the instrument panel bracket with the fastening screws 1 2 Fastening screws 13 Undo fastening screws 2 from the instrument panel 4 Screw the instrument panel 4 to t...

Page 1080: ...replace if necessary 6 Instrument panel bracket with knee protector strip 1 7 Sheetmetal nut 11 Unscrew fastening screws 1 and 2 from the instrument panel 4 Inspect and replace if necessary top of pa...

Page 1081: ...anel bracket and screw down with the fastening screws 8 and 11 13A Closure cap 2 Pull out Press in 13B Plug 2 Only installed on 911 coup versions 14 Sheetmetal clip 4 Check if necessary replace 15 Fas...

Page 1082: ...htening torque Nm ftlb A pillar fastening screws on the instrument panel bracket 8 M8 23 17 Nm ftlb Cowl panel fastening screws on the instrument panel bracket 11 M6 10 7 5 Nm ftlb Knee protector stri...

Page 1083: ...l designation Remarks 1 Socket wrench insert 9259 Gr 2 2 Workshop Equipment Manual 2 Adhesive pad commercially available Teflon adhesive tape Cutting with adhesive pad 996420 996421 996450 996451 9968...

Page 1084: ...panel for model year 2002 model care The instrument panel has a glove compartment and a cupholder The procedures described in the following are to be carried out for repair work on the components mode...

Page 1085: ...g the alarm readiness cover and the defroster cover Lift the alarm readiness cover 3 and unclip it upwards out of the clip 4 The lens cover 2 can be unclipped for replacement purposes Lift the defrost...

Page 1086: ...ight switch 13 is held in the instrument bridge 17 by two locking hooks arrow B Press the right locking hook towards the switch grip the button holder with a pair of pliers and pull out the switch tow...

Page 1087: ...tton 25 of the light switch 31 as far as it will go direction of the arrow towards the front Press in the locking device at the lower side using a small screwdriver and remove the control button towar...

Page 1088: ...plug connection In order to disassemble the steering column switch 42 the slip ring 41 can be disconnected by undoing the fastening screws 39 40 See 695419 Removing and installing the contact unit 10...

Page 1089: ...rrow B of the retaining bracket 52 and guide it out of the cut out of the center nozzle 55 Pull off the ground cable 53 15 Removing the center nozzle Undo the fastening screws 54 and guide the center...

Page 1090: ...the lights bracket arrow B out to the side with a narrow screwdriver 3 Disengage the cigarette lighter in the direction of arrow C out of the front cover top of page Assembling the instrument panel e...

Page 1091: ...nd secure with the fastening screws 56 Position the center nozzle 55 in the instrument panel and secure with the fastening screws 54 Additional assembly notes for the cover and center nozzle for the i...

Page 1092: ...ommunication system 48 See 870219 Removing and installing the heating air conditioning regulator See 912019 Removing and installing the car radio 5 Installing the switch covers Plug in the electrical...

Page 1093: ...the steering column switch cover at the top 33 9 Installing left side nozzles and main light switch Connect the electrical plug connection 30 of the main light switch 31 Position the inner race 27 in...

Page 1094: ...sert instrument mount in the clip 4 Secure with the fastening screws 16 Place button 12 in position If the vehicle is equipped with a handsfree telephone connect the microphone plug connection instead...

Page 1095: ...the wiping interval into the front cover from the front Ensure that the locking tabs A have engaged 2 Plug in the electrical plug connection Installing the cigarette lighter 1 Press the illumination...

Page 1096: ...de of the cover 1 and press out b Insert the second plate of the center nozzle into the metal clip 3 using a small screwdriver 2 Press and hold screwdriver upwards in the direction of arrow and simult...

Page 1097: ...in locking tab on the cover 1 using a screwdriver Pull out center nozzle 2 Removing holder 1 Removing holder Unscrew fastening screws 1 from the holder A or B Installing holder einordnung Removing cov...

Page 1098: ...ol switches must be correctly mounted before the cover is fitted Particular care is required when clipping in finished covers The finished covers of the Exclusive or Tequipment range carbon fibre comp...

Page 1099: ...lling cover and center nozzle b Push the cover 1 with the center nozzle 2 into the instrument panel ensuring that the clips are engaged at the top and the locking tabs at the side 996420 996421 996450...

Page 1100: ...70 22 19 Removing and installing cowl panel cover Removing and installing cowl panel cover top of page Removing and installing cowl panel cover 70 22 19 Removing and installing cowl panel cover 1037...

Page 1101: ...crew T25 M5 x 30 2 4 Radiator tank cover right 1 5 Radiator tank cover left 1 6 Dummy press in nut 2 7 Cam 2 Unclip Clip in 8 Cap 2 Position and press in With a small screwdriver 9 T5 plastic nut 2 Ch...

Page 1102: ...nd separate electrical plug connection Connect electrical plug connection 19 Spray nozzle 2 Use a screwdriver to lift the spray nozzle at the front edge Pull off water hose Push on water hose and pres...

Page 1103: ...door trim panel Installing door trim panel Installation note for door sealing film Fitting sliding strip on the inner door panel Materials and tools Tightening torque top of page Removing door trim pa...

Page 1104: ...d assembly work or work on the vehicle may be started after a waiting period of 1 minute CAUTION Damage by bending the bowden cable at the hook The hook of the bowden cable is pressed into the end pie...

Page 1105: ...ss lugs of the plastic clip arrow A and pull out towards the rear Push bowden cable 8 back into the end piece of the sleeve arrow B 4 Removing door trim panel Unscrew expanding nut from the door trim...

Page 1106: ...ached using a butyl sealing cord No Procedure Instructions 1 Installing sound box Position sound box 23 in the door Screw on the sound box with the fastening screws 22 Connect electrical connection 21...

Page 1107: ...clips 13 14 must be replaced every time the door trim panel is removed Position the door trim panel on the door and clip it in 7 Installing the airbag plastic cover Position fastening screws 5 in the...

Page 1108: ...page Fitting sliding strip on the inner door panel A sliding strip must be stuck onto the front and rear sides of the inner door panel in order to prevent creaking noises from the door area 1 Sticking...

Page 1109: ...op of page Materials and tools Item Designation of the special tool Remarks 1 Butyl sealing cord to reaffix the door film Spare parts Gr 8 07 10 Parts Catalogue top of page Tightening torque Location...

Page 1110: ...ng and installing oddments compartment lid Removing and installing oddments compartment lid top of page Removing and installing oddments compartment lid 70 65 19 Removing and installing oddments compa...

Page 1111: ...the door panel 1 and guide mechanism 6 and push in shaft 3 until it engages at the groove 4 Lid for oddments compartment 1 To remove lid for oddments compartment 4 see Item 3 5 Oval head screw 4 2 x...

Page 1112: ...B 4 2 x 14 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Removing and installing oddments compartment lid 1049...

Page 1113: ...70 84 19 Removing and installing roof lining Removing roof lining Installing roof lining top of page Removing roof lining 70 84 19 Removing and installing roof lining 1050...

Page 1114: ...lenses at the openings provided Undo fastening screws M5 with a crosshead screwdriver arrow A Unclip cover at the rear left and right arrow B push forward towards the windshield and remove Disconnect...

Page 1115: ...e rear out of the roof frame evenly on the left and right and disengage 6 Disengage the metal strut Pull the metal brace contained in the fabric pocket down in the centre so that it bends Pull the met...

Page 1116: ...ent At the same time pull the frame backwards in the centre at the front of the sliding roof cut out so that the frame overlap at the corners is reduced and it is possible to insert the frame into the...

Page 1117: ...w in cross recess screw Press in the cover of the bracket until it engages 6823 Removing and installing sun visors 8 Remove interior light cover Connect the electrical plug connection of the sliding r...

Page 1118: ...nger with a commercially available hose clamp Loosen heater hoses on the heat exchanger and pull off arrows 6 Carefully remove cover over the heat exchanger 7 Release heat exchanger arrows and pull it...

Page 1119: ...t 1 Remove footwell bulkhead and right air guide 2 Pull off electrical plug connection on the blower motor arrows and remove wire from the holder 3 Pull off electrical plug connection on the ballast r...

Page 1120: ...air blower motor 1 Install blower motor and fasten housing lid 2 Tighten fastening screws carefully plastic housing 3 Engage electrical plug connections and perform a function test 996420 996421 99645...

Page 1121: ...gs so that they are air tight WARNING Danger of injury if airbag units are triggered while ignition key is not removed Always remove ignition key during body work and do not commence work until a wait...

Page 1122: ...tion key is not removed Always remove ignition key during body work and do not commence work until a waiting period of at least 1 minute has elapsed 14 Remove the air guide at the bottom right 15 Remo...

Page 1123: ...der of the heater air conditioning unit from the passenger s side at the top right arrow 27 Carefully lower the heater air conditioning unit downwards into the footwell and remove Do not damage the el...

Page 1124: ...removed from a previously run air conditioning system may no longer be used special category waste 5 Replace the rings for the refrigerant lines at the expansion valve and wet the new rings with refr...

Page 1125: ...the system test 1 Unclip cover 2 Unscrew fastening screws 2 ea and pull the heating air conditioning control out of the dashboard 3 Disconnect the electrical plug connections top of page Performing sy...

Page 1126: ...as a fault if necessary Two different voltage values are set on the fresh air blower and tested The A C circuit is tested via the DME All fault paths are tested and any faults are stored Basic adapta...

Page 1127: ...ning off old refrigerant oil Evacuating Topping up with new refrigerant oil Filling via the high pressure side Refilling the air conditioning system Distribution of the oil quantity in the refrigerant...

Page 1128: ...ff valve red 6 Torr meter shut off valve black 7 Vacuum pump shut off valve yellow 8 Low pressure flange 9 High pressure flange 10 Refrigerant inlet shut off valve 11 Refrigerant outlet shut off valve...

Page 1129: ...when handling refrigerant R134a During all work on the air conditioning system which necessitates opening the refrigerant system the system contents must first be disposed of correctly Dirt and moistu...

Page 1130: ...part 3 Evacuate 4 Check the system for leaks 5 Rinse with refrigerant 6 Empty the system by suction again 7 Evacuate 8 Fill top of page Removing refrigerant by suction and cleaning Note Close all valv...

Page 1131: ...ling cylinder into a refrigerant bottle approx 50 top of page Cleaning the refrigerant A Close B Open Cleaning start End 1 ON OFF 3 CLEAN END 2 SUCTION CLEAN 4 ON OFF Pressure too high filling cylinde...

Page 1132: ...A Close B Open 1 ON OFF Instructions 1 open to 2 OFF then 1 CLOSED and 3 OPEN top of page Evacuating A Close B Open 1 ON OFF einordnung Draining off old refrigerant oil 1069...

Page 1133: ...2 VACUUM PUMP Evacuation time at least 15 minutes top of page Topping up with new refrigerant oil A Close B Open 1 ON OFF top of page Filling via the high pressure side einordnung Evacuating 1070...

Page 1134: ...system Note In the event of insufficient refrigeration performance remove the refrigerant by suction top up with the stipulated quantity and check the system for leaks 1 Remove the refrigerant by suc...

Page 1135: ...he oil quantity must be determined and topped up by the quantity remaining in the removed component Oil quantity Total oil quantity 195 15 cm3 After suction removal from the system the following quant...

Page 1136: ...ture valve and central valve Drive motor for temperature valve Drive motor for central valve 1 Remove footwell bulkhead and air guides Unclip centre console cover at the front and remove the footwell...

Page 1137: ...nstalled heating air conditioning unit in this position recirculation 2 Remove footwell bulkhead and right air guide 3 Disconnect electrical plug connection of the drive motor and undo fastening screw...

Page 1138: ...nnot be changed Ensure that the deflection lever of the outside air valve is seated correctly 1 Tighten fastening screw carefully plastic housing 2 Engage electrical plug connection and route wire car...

Page 1139: ...re plate can be removed manually 3 Remove the spacer washers 4 Use standard Seeger circlip ring pliers to remove the Seeger circlip ring Manually remove the belt pulley 5 Unscrew the cable of the magn...

Page 1140: ...outer edge of the belt pulley and use a depth gauge to measure up to the pressure plate Note Always measure at at least three points on the pressure plate in order to obtain a mean value Distance 0 5...

Page 1141: ...complete air cleaner assembly 6 Remove the pressure pipe to the throttle body and disengage frequency valve on the holder 7 Just loosen belt pulley for hydraulic pump Relieve the drive belt at the ten...

Page 1142: ...Empty approx 80 cm3 of refrigerant oil out of the compressor and into a measuring glass The remaining quantity of oil approx 120 cm3 remains in the compressor 4 Always replace the sealing ring Tighten...

Page 1143: ...r conditioning system fluid via the high pressure side from the refrigerant circuit with the engine OFF 1 If possible all air outlet nozzles OPEN circulating air CLOSED 2 Start the engine and allow id...

Page 1144: ...out of the holder top of page Installing the condenser Note Refrigerant oil removed from a previously run air conditioning system may no longer be used special category waste 1 Do not remove the plug...

Page 1145: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing the condenser 1082...

Page 1146: ...off the radiator bracket downwards 4 Disconnect the electrical plug connection and undo 2 sheetmetal screws from the fan housing 5 Pull the fan housing with fan motor out of the holder 6 Detach fan mo...

Page 1147: ...t be replaced if the system suffers from operational faults e g accident damage or air conditioning system depressurised Used refrigerant oil extracted from a previously run A C unit must not be re us...

Page 1148: ...ootwell vent 3 screws 3 Turn blower outlet sensor by 90 and pull it out 4 Pull electrical plug connection off blower outlet sensor top of page Installing footwell blower outlet sensor 1 Position tempe...

Page 1149: ...for fresh air recirculation valve 3 Pull off electrical plug connection on the outside temperature sensor 4 Turn temperature sensor by 90 and pull it out top of page Installing outside temperature sen...

Page 1150: ...ht 4 Undo the expansion valve arrow and remove Immediately close the lines to the evaporator with plugs so that they are air tight top of page Installing expansion valve Note Refrigerant oil removed f...

Page 1151: ...iver out of the upper bracket and remove in downward direction 4 Pull off electrical plug connection top of page Installing blower driver 1 Engage the electrical plug connection and slide the blower d...

Page 1152: ...is located behind the cover 3 Press locking tabs together slightly and remove temperature sensor from the dashboard 4 Pull off electrical plug connection top of page Installing interior temperature se...

Page 1153: ...ing the service unit 3 Pull off the cable plug arrow on the pressure switch 4 Undo and unscrew the pressure switch top of page Installing pressure switch for the air conditioning system Note Refrigera...

Page 1154: ...trument cluster 1 Select vehicle type 911 Turbo 996 2 Select control modules 3 Select instrument cluster 4 Select total mileage 5 Input Vehicle Identification Number 6 Confirm with F7 key 7 Input kilo...

Page 1155: ...he instrument cluster should not be disassembled The bulbs have been replaced with LEDs The instrument cluster can be replaced as a complete unit only 996420 996421 996450 996451 996620 996621 996650...

Page 1156: ...denser Horn A Horn high pitch B Horn low pitch top of page Removing horn Note The high pitch horn can be removed from below through the sound outlet opening The entire front spoiler must be removed in...

Page 1157: ...Installing horn 1 Observe installation position of the horns The horn must not touch the body or a bracket A toothed washer must be fitted between the horn and bracket Tightening torque of the M6 hexa...

Page 1158: ...loses the so called almanac The almanac stores the satellite orbits and ensures fast location of the individual satellites when the system is started top of page Distance sensor Note The distance sens...

Page 1159: ...km h for a distance of approx 50 km calibration of the distance measurement 3 Drive approx 10 km in an urban area and take frequent turn offs 4 Stop for approx 10 seconds occasionally calibration of t...

Page 1160: ...ial tool V 160 into the recesses of the navigation unit and engage 3 Carefully push out the navigation unit rearward and disconnect plug connections top of page Installing navigation unit 1 Engage the...

Page 1161: ...Only the navigation code has to be input again if the navigation unit is exchanged 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Device code input 1098...

Page 1162: ...GPS antenna must not be covered by metallic or moist objects top of page Removing GPS antenna 1 Unclip cover from behind and take out 2 Undo both Torx T20 fastening screws with an angled screwdriver...

Page 1163: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Installing GPS antenna 1100...

Page 1164: ...ct the electrical plug connections top of page Installing the car radio 1 Remove the heating air conditioning control Rep Gr 870219 Removing and installing the heating air conditioning control 2 Engag...

Page 1165: ...her numbers were correct the device switches itself on automatically Note The CODE CARD must always be stored without fail outside the vehicle in a safe place In this way improper use can be excluded...

Page 1166: ...eft and right and remove the cowl panel cover upwards over the wiper link 4 Undo the radio antenna under the cowl panel cover and unclip it top of page Installing radio antenna 1 Clip in the radio ant...

Page 1167: ...ration Position 3 Active operation top of page Setting Note The setting as delivered in new cars is position 3 1 Carefully unclip hands free microphone from the dashboard insert and pull out 2 Use a s...

Page 1168: ...on A toward the front 4 Unclip the collar from the dashboard insert The hazard warning light switch B is held in the dashboard insert by two locking hooks 5 Press the right locking hook toward the swi...

Page 1169: ...to the dashboard 2 Install hazard warning light switch 3 Press button A onto the hazard warning light switch B until the button is heard to engage 4 Clip in hands free microphone connect the battery a...

Page 1170: ...r thickness max 120 m top of page Removing sensor for ParkAssistent 1 Take off rear spoiler 2 Pull off electrical plug connection 3 Slightly bend up the holding peg on the sensor housing and push out...

Page 1171: ...sistent control module Note The control module is fastened next to the alarm system central locking system control module under the driver s seat When removing remove the seat and detach the retaining...

Page 1172: ...motor 3 M6 screws and the lower fastening screw on the body 6 Carefully raise the wiper link and remove the wiper motor downwards 7 Disconnect the electrical plug connection on the wiper motor top of...

Page 1173: ...Tightening torque Hexagon head bolt M6 10 Nm 7 5 ftlb 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing wiper motor 1110...

Page 1174: ...link 4 Remove the left dome strut 5 Undo the wiper link on the body 3 M6 screws and disconnect the electrical plug connection on the wiper motor 6 Carefully remove the wiper link with wiper motor to...

Page 1175: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing wiper link 1112...

Page 1176: ...ht hand drive vehicles A Passenger s side B Driver s side Note The spoiler edge on the wiper blade on the driver s side must face downwards The clip installation position must be observed when install...

Page 1177: ...per arm 3 Remove the rear panel cover in front of the rear window wiper motor 4 Undo the retaining frame with rear window wiper motor at the rear centre panel 2 nuts 1 screw and pull out to the front...

Page 1178: ...tem Removing and installing tank for windscreen washer system 2 Remove hose to the spray nozzles at the tank and turn the pump outlet to the rear 3 Lift pump upwards out of the rubber sleeve 4 Pull ho...

Page 1179: ...the headlight cleaner nozzle at the headlight holder 4 Carefully pull off the hose for the windscreen washer system 5 Undo fastening screws and swing the holder inward 6 Pull tank forward out of the...

Page 1180: ...torque of the hexagon head bolts M6 x 20 10 Nm 7 5 ftlb Tightening torque of the hexagon head bolts M8 x 35 20 Nm 15 ftlb 4 Engage hose for the headlight cleaning system and carefully push on the hose...

Page 1181: ...and installing tank for windscreen washer system 2 Pull sensor for fluid level indicator out of the tank to the side top of page Installing fluid level indicator 1 Check rubber sleeve for sensor repla...

Page 1182: ...headlight washing system and hold nozzle head 2 Use a screwdriver to unclip and remove the spray nozzle head arrow top of page Installing cover for spray nozzle 1 Insert cover with spray nozzle head i...

Page 1183: ...headlight housing and pull the spray nozzle out of the headlight housing top of page Installing spray nozzle for headlight washing system 1 Install the spray nozzle in the headlight housing 2 Make su...

Page 1184: ...nstalling tank for windscreen washer system 2 Remove hose to the spray nozzles at the tank and turn the pump outlet to the rear 3 Remove spacer between the pumps and lift pump upwards out of the rubbe...

Page 1185: ...ide with a small screwdriver 3 Undo three 4 0 x 18 Torx screws of the left side vent and carefully pull the side vent out of the dashboard One Torx screw is located in the light switch on the right 4...

Page 1186: ...direction Tightening torque of the hexagon nut M16 x 1 3 5 Nm 2 5 ftlb 2 Engage electrical plug connections and install side vent 3 Connect the battery and perform a function test 996420 996421 996450...

Page 1187: ...have a high voltage Note For a faulty dipped beam or high beam headlight the individual components gas discharge lamp control module can be replaced from the second headlight Only the battery voltage...

Page 1188: ...actory A new adjustment may only be made in the case of accident repairs or replacement of the main headlights top of page Adjustment instructions Note The headlight cover plate should lie approximate...

Page 1189: ...ment procedure 1 Adjust fastening nuts to the same height as the old version and tighten slightly by hand Mounting plate removed 2 Press headlight housing firmly into the body and lock 3 After adjustm...

Page 1190: ...film for left right hand traffic should not be removed from Xenon headlights In the headlight there is a changeover lever for driving in countries with left or right hand traffic The changeover lever...

Page 1191: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Installation 1128...

Page 1192: ...ron or film A Open B Close The tool kit contains a wrench for opening and closing the headlights 1 When installing press headlights firmly into the wing 2 Secure the plugs after installation 996420 99...

Page 1193: ...n when changing the lamp Do not touch the glass bulb top of page Removing gas discharge lamp Xenon headlights 1 Switch off light Remove main headlight 2 Unscrew fastening screws 2 ea and open rear clo...

Page 1194: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing gas discharge lamp Xenon headlights 1131...

Page 1195: ...b socket out of the headlight reflector do not pull on the wires 3 Unscrew defective bulb from the parking light bulb socket bayonet lock top of page Installing bulb for parking light 1 Install new bu...

Page 1196: ...h back the rubber cover and remove defective bulb from between the contact springs top of page Installing bulb for number plate light 1 Insert new bulb in the holes of the contact springs 2 Push the r...

Page 1197: ...indicator light 3 Turn bulb socket counter clockwise and remove from the tail light 4 Take defective bulb out of the bulb socket bayonet lock top of page Installing bulb for tail light 1 Install new b...

Page 1198: ...the button A toward the front 3 Unclip the collar from the dashboard insert The hazard warning light switch B is held in the dashboard insert by two locking hooks 4 Press the right locking hook toward...

Page 1199: ...screwdriver 3 Release and pull off electrical plug connection 4 Turn bulb socket counter clockwise and remove bayonet lock 5 Remove defective bulb top of page Installing bulb for side direction indic...

Page 1200: ...mp should only be operated when installed in the reflector and in the installed headlight A removed headlight does not have a high voltage top of page Removing control module for gas discharge lamp 1...

Page 1201: ...mp 1 Engage electrical plug connection 2 Clip in wiring arrangement and check for correct seating 3 Fasten holder with control module 4 Close cap and secure with fastening screws 5 Install main headli...

Page 1202: ...in headlight 2 Unscrew fastening screws 2 ea and open rear closure cap Unscrew bulb for the auxiliary headlight bayonet lock 3 Release and disconnect electrical connection of the defective bulb top of...

Page 1203: ...al plug connection arrow from the defective bulb 4 Press down retaining bracket arrow and swivel to the left 5 Remove defective bulb top of page Installing bulb for fog light 1 Install new bulb and en...

Page 1204: ...lockwise and remove 4 Disconnect electrical plug connection and disengage all fastening tabs of the bulb holder 5 Remove bulb holder and take out defective bulb top of page Installing bulb for additio...

Page 1205: ...l plug connection and remove electrical plug connection from the angle sensor 4 Detach retaining bracket for angle sensor from the side member underneath 5 Detach the angle sensor from the retaining b...

Page 1206: ...connection protects against water leaking in 3 Secure the linkage to the rotary lever and install underside panel Tightening torque 7 Nm 5 ftlb Adjust the main headlights 0 Entire vehicle General 9964...

Page 1207: ...e angle sensor from the retaining bracket and remove it top of page Installing rear angle sensor for headlight beam adjustment Note Once the angle sensor has been installed the control module must be...

Page 1208: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing rear angle sensor for headlight beam adjustment 1145...

Page 1209: ...adlight beam adjustment 1 Switch off light Remove main headlight 2 Unscrew fastening screws 2 ea and open rear closure cap 3 Disconnect the electrical plug connection from the drive motor and undo the...

Page 1210: ...l plug connection and take out control module top of page Installing control module for headlight beam adjustment Note Once installed the control module must be coded and calibrated with the Porsche S...

Page 1211: ...ight carefully using a screwdriver 2 Remove bulb socket from the door warning light and remove defective bulb top of page Installing bulb for door warning light 1 Insert new bulb in the bulb socket an...

Page 1212: ...nd remove 4 Remove defective bulb from between the contact springs top of page Installing bulb for interior light 1 Insert new bulb for the reading light in the bulb socket and install bayonet lock 2...

Page 1213: ...carefully out of the trim panel using a screwdriver 2 Remove defective bulb from between the contact springs top of page Installing bulb for luggage compartment light 1 Insert new bulb in the holes o...

Page 1214: ...carefully out of the fan cover using a screwdriver 2 Remove defective bulb from between the contact springs top of page Installing bulb for engine compartment light 1 Insert new bulb in the holes of t...

Page 1215: ...s is less than 1024 it is possible to perform re synchronisation Re synchronisation is carried out according to the following procedure Switch on ignition with key and valid transponder Switch off ign...

Page 1216: ...not activated in this case This also applies for the Belgian market if the vehicle was parked unlocked for longer than five days If the radio receiver has been deactivated it can be reactivated only b...

Page 1217: ...mall screwdriver 2 Lift out the cap and relieve the compression spring 3 Push the sliding latch back and pull the key out of the bottom part top of page Installing key in the bottom part 1 Insert repl...

Page 1218: ...or the hand held transmitter is faulty all keys still in the customer s possession will be required The following information is required to teach the hand held transmitter Key learning code from IPAS...

Page 1219: ...smitter It is essential to identify and delete the transponder code of the lost hand held transmitter as described in step 8 b It is essential to identify and delete the radio code of the lost hand he...

Page 1220: ...h the control module Current radio key shows the radio code of the vehicle key that is presently inserted in the ignition lock Compare this radio code with the radio codes at positions 1 to 4 This com...

Page 1221: ...dashboard 1 Disconnect the battery and cover terminal or battery 2 Remove left side nozzle Removing and installing main light switch 3 Open the locking button with a short cross head screwdriver 1 4 t...

Page 1222: ...al converter housing 1 4 turn clockwise 2 Engage electrical plug connections and install side vent 3 Connect the battery and perform a function test 996420 996421 996450 996451 996620 996621 996650 99...

Page 1223: ...sor holder at the rear left and right B push forward towards the windshield and remove 4 Pull off electrical plug connection 5 Unclip passenger compartment monitoring sensor at the side and remove fro...

Page 1224: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Removing and installing passenger compartment monitoringsensor 1161...

Page 1225: ...adiator tank After repair the following function tests must be performed ABS Test with the Porsche System Tester 2 BVA The indicator light must go out with the engine running and the brake linings int...

Page 1226: ...nd sides of wires Wire 1 br gn Wire 2 br bk Wire 3 br Wire 4 br bu Wire 5 br wt br brown bk black bu blue wt white gn green 3 Cut wires to the correct length in the area of the disconnection point Com...

Page 1227: ...1 Wrap commercially available PVC tape all around the area of the connection points 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing main wiring harness 1164...

Page 1228: ...S Test with the Porsche System Tester 2 BVA The indicator light must go out with the engine running and the brake linings intact Plug connection X 2 4 Pfeil passenger compartment rear end Install prea...

Page 1229: ...n Wire 2 br bk Wire 3 br Wire 4 br bu Wire 5 br wt br brown bk black bu blue wt white gn green 4 Unlocking tool to unlock the old contacts in the plug connection see Workshop Equipment Manual No 155 5...

Page 1230: ...16 Push on heat shrinking tube 17 Using a crimp connector join brown green wire of combination wire to brown green wire of rear end wiring harness 18 Shrink heat shrinking tube with a hot air gun so t...

Page 1231: ...the engine retainer plate in the necessary horizontal position 4 Support plate with wooden supports 9111 4 Separate the wooden supports and only fasten one half in each case on the support plate 5 Ad...

Page 1232: ...N Danger of material damage if the vehicle is raised incorrectly Raise the vehicle at the prescribed jacking points Raise the vehicle by means of a workshop jack on the engine and move the mounting pl...

Page 1233: ...ove the complete air cleaner assembly 8 In order to remove the pressure pipe loosen the hexagon head bolts the hose clamp and the plug 9 Disconnect vacuum hose from the switchover valve and remove the...

Page 1234: ...4 Remove belt pulley 15 Disconnect the hydraulic lines with plug in coupling on the expansion tank Note Wear protective gloves Collect emerging Pentosin Protect the line against dirt and scratches wit...

Page 1235: ...ote Always use the protective support Disconnect the electrical plug connection Lift out compressor and set it down with the hoses connected 21 Undo engine wiring harnesses 2 round connectors with bay...

Page 1236: ...the two upper hexagon head bolts M12 x 83 there are slots in the cross member Note Remove hexagon head bolts in order to avoid damage to the reference mark sender cable or the oil tank when the engin...

Page 1237: ...th removal tool Workshop Equipment Manual Chapter 2 4 No 21 34 Remove starter Pull off protective cap Detach terminals 30 and 50 Undo upper fastening screw with 3 8 inch tool two short extensions univ...

Page 1238: ...ctuate clutch pedal at least 25 times Note The joint is located on the rear left side member inside When undoing the screw coupling at the screw connection A counter simultaneously at screw connection...

Page 1239: ...support 44 Separate engine carrier from the engine mounts wrench size 18 45 Carefully and in steps lower the engine transmission unit by approx 10 cm 46 The following parts must be undone or removed...

Page 1240: ...rrow Undo the fuel supply line 1 and fuel return line 2 in the engine compartment left Disengage fuel filter Note Always counter when undoing the fuel supply line and fuel return line 48 The intake ai...

Page 1241: ...second person observe the engine transmission clearance especially in the area of the oil container and the detached intake air distributor If the vehicle is placed on its wheels or moved in the works...

Page 1242: ...rve the engine transmission clearance during lifting Pay particular attention to the clearance between rear axle cross member intake air distributor and oil container 2 The following assembly work mus...

Page 1243: ...distance of A 20 mm between the holders of the spring band clamps and the fuel line If necessary set this distance with a spacer during the tightening process Push on vacuum line for the brake booster...

Page 1244: ...re engaging the coolant hoses 10 Move coolant hoses into installation position Note The coolant hoses must audibly engage when pushed into the flanges 11 Fit pressure hoses between the charge air cool...

Page 1245: ...4 130 96 Rear axle member to carrier side section M12 110 81 Cross member at front to carrier side section M10 65 48 Diagonal brace to body M10 65 48 Diagonal brace to cross member M12 110 81 Diagonal...

Page 1246: ...ipheral equipment Removing and installing injection valves Engine installed As fuel may emerge from the fuel collection pipe a cloth or similar should be placed around the injection valves top of page...

Page 1247: ...f page Installing injection valves of cylinder bank 1 3 Note If the injection valves are not replaced the sealing rings of the injection valves must be checked and replaced if necessary 1 Coat the sea...

Page 1248: ...d 3 Press the fuel collection pipe ont to the injection valves A 4 Install the tab washers B of the injection valves Ensure correct seating 5 Fasten the fuel collection pipe To do so screw in and tigh...

Page 1249: ...radio code 3 Disconnect the battery and cover terminal or battery 4 Remove rear spoiler 63 55 19 Removing rear spoiler 5 Remove air cleaner housing Removing and installing air cleaner top of page Rem...

Page 1250: ...de CAUTION Do not lower engine too far To avoid damage to the hoses leads and engine the engine must only be lowered by approx 30 mm 40 mm 7 Lower engine Secure the engine against falling down with a...

Page 1251: ...the entire overrun air valve module Figure 11 Pull the vent line off the coolant expansion tank 12 Remove fuel filter Replacing fuel filter 13 Loosen and unscrew the three fastening screws arrows at t...

Page 1252: ...mshaft adjustment valve Note With all fuel lines always counter with a second open ended wrench 18 Disconnect the fuel return line 2 a f 14 and 17 Unscrew the M6 screw in the holder 3 19 Disconnect th...

Page 1253: ...oses leads and engine the engine must only be lowered by approx 30 mm 40 mm 4 Lower engine Secure the engine against falling down with a workshop jack Undo the two hexagon nuts on the right and left o...

Page 1254: ...he engine compartment on the right and lay to one side 11 Remove the secondary air pump Removing and installing secondary air pump 12 Pull off the vacuum hose on the fuel pressure regulator and lay it...

Page 1255: ...ction pipe 18 Remove the tab washers of the injection valves and pull the injection valves out of the fuel collection pipe top of page Installing injection valves 1 Always fit new sealing rings on the...

Page 1256: ...Carefully insert the injection valves into the openings in the intake pipe 5 Fasten the fuel collection pipe Put on and tighten the two M6 screws 3 for this purpose Tightening torque of M6 screws 10 N...

Page 1257: ...valve 13 Place the fuel collection pipe with the injection valves of cylinder bank 1 3 in position on the left intake distributor Connect connectors of the injection valves Carefully insert the inject...

Page 1258: ...ghtening torque 30 Nm 22 ftlb 18 Position and tighten the fuel return line 2 a f 14 and 17 Position the M6 screw in the holder 3 but do not tighten yet Tightening torque return line 30 Nm 22 ftlb 19 C...

Page 1259: ...e into contact with the body or any other components 23 Connect the battery 24 Connect the Porsche System Tester and switch on the ignition 25 Then activate the fuel pump with the Porsche System Teste...

Page 1260: ...ront intake pipe connector Tightening torque of M6 screws 10 Nm 7 5 ftlb 37 Position and tighten the upper screw right arrow Tightening torque of M6 screw 10 Nm 7 5 ftlb 38 Tighten the M6 screw in the...

Page 1261: ...e vent line of the coolant expansion tank Fasten hose clamp 44 Fasten the engine to the engine mounts again To do so raise the lowered engine with the workshop jack to its final position position and...

Page 1262: ...ue of M6 screw 10 Nm 7 5 ftlb 49 Connect hose to the Y shaped pipe and fasten with the hose clamp arrow 50 Install the connecting hoses between the charge air coolers and the Y shaped pressure pipe th...

Page 1263: ...op of page Tools Item Designation of the tool Remarks Open ring wrench for oxygen sensor Hazet 4681 3 Gr 2 4 No 98 Workshop Equipment Manual Torque wrench 1 2 Wille 730 R 12 or Torque wrench 1 2 Hazet...

Page 1264: ...rectangular 2 Plug for sensor behind catalytic converter oval Note Observe precautionary measures when using oxygen sensors Oxygen sensor left side 1 Remove air cleaner housing Removing and installing...

Page 1265: ...c securing clip 3 Unclip the oxygen sensor wire in front of the catalytic converter from the wire guide and the sheetmetal clips Note Always expose oxygen sensor wire so that the wire can turn when un...

Page 1266: ...sensor wire and fix in the sheetmetal clips and wire retainers on the left and right 4 Close rectangular plug connections and secure with plastic clip 5 Install the air cleaner housing again Removing...

Page 1267: ...ng the DME control module Programming the new DME control module 911 Turbo 996 Programming the new DME control module GT2 and version X51 Programming the DME control module 911 Turbo 996 Programming D...

Page 1268: ...Switch ignition on to continue 2 Select vehicle type using the cursor keys 3 Using the key move from the vehicle type to the list of control units 4 Select DME with the cursor keys and press the key...

Page 1269: ...rews on the control module holder 3 and remove the control module top of page Installing the DME control module 1 Fasten the control module on the control module holder with the four fastening screws...

Page 1270: ...ber During DME programming it is essential to guarantee the power supply for the Porsche System Tester In case of doubt connect a charging unit to the vehicle battery Symbol for the TAB key Follow the...

Page 1271: ...he DME code specified in IPAS and the immobilizer code must be entered in the DME control module You can get the codes from IPAS or from your importer by specifying the vehicle identification number I...

Page 1272: ...17 When the programming period has expired follow the instructions from the Porsche System Tester CAN TIME OUT 18 Press the key For the learning and adaptation routine of the throttle E gas switch the...

Page 1273: ...lect the required program map and confirm with the key Version data records 911 Turbo 996 13 The data status is loaded on to the DME control module Do not interrupt the programming sequence 14 When th...

Page 1274: ...DME IPAS vehicle OLD programming code with the cursor keys continue with the key and after checking the code confirm with F7 9 Enter the new DME IPAS vehicle NEW programming code with the cursor keys...

Page 1275: ...is to be done in the context of a campaign In the case of Up to date the data record and the version are displayed Type Diagnosis software no Version Remarks M 150 2201 Manual transmission Tiptronic C...

Page 1276: ...erequisite is that a customer complaint has been submitted or that Porsche AG has arranged for this to be done in the context of a campaign In the case of Up to date the data record and the version ar...

Page 1277: ...ch the sheetmetal holder from the transmission flange lid 1 screw M6 7 Disengage the sheetmetal holder and the plastic holder from the coolant hoses 8 Pull the coolant lines under the front transmissi...

Page 1278: ...g torque for M8 hexagon nut 15 Nm 11 ftlb M6 screw 6 5 Nm 5 ftlb Tightening torque of the hexagon head bolt M10 46 Nm 34 ftlb 3 Push protective cap over the solenoid switch and engage in the B lead 4...

Page 1279: ...ll in the guarantee period 3 years the letter R must be imprinted after the transmission number Note Use the Damage Catalogue to diagnose the damage in the transmission top of page Tools Item Special...

Page 1280: ...nt Manual Chapter 2 4 No 105 top of page Removing transmission cover 1 Remove transmission 34 35 27 Removing and refitting the transmission 2 Fasten the transmission on assembly support 3 Drain transm...

Page 1281: ...ndrical roller bearing 1 4 Thrust plate 1 5 Loose gearwheel reverse gear 1 6 Synchronising ring 1 7 Needle roller bearing 1 8 Bearing inner race 1 9 Shift collar 1 10 Washer 2 11 Hexagon head bolt 2 1...

Page 1282: ...6th gear 1 29 Needle roller bearing 1 30 Bearing inner race 1 31 Thrust plate 1 32 Hexagon nut self locking 1 33 Bearing inner race 1 34 Fixed gearwheel reverse gear 1 35 Spacer sleeve 1 36 Fixed gear...

Page 1283: ...ing the puller If necessary press the bearing inner race forwards again with the mounting lever 9 Open up shift fork and remove complete synchonization 10 Remove fixed gear wheel 5th gear no 36 in ove...

Page 1284: ...with a rubber hammer top of page Removing input and output shaft Overview No Designation Qty 1 Cylindrical roller bearing 1 2 Thrust plate 1 3 Loose gear wheel 1st gear 1 4 Friction ring 1 einordnung...

Page 1285: ...ar 1 26 Selector shaft 1 27 Shift rod 5th 6th gear 1 28 Tensioning plate 1 29 Hexagon nut 7 30 Shift rod 3rd 4th gear 1 31 Cylindrical roller bearing 1 32 Screw plug 4 33 Spring 4 34 Ball 4 35 Adjusti...

Page 1286: ...erview with synchronisation 1st 2nd gear no 16 to 4 in overview and loose gearwheel for 2nd gear no 17 in overview 7 Remove selector shaft no 26 in overview Note A specific disassembly of the synchron...

Page 1287: ...g inner race 1 4 Four point bearing 1 5 Tensioning plate 1 6 Bearing inner race 1 7 Shift rod 3rd 4th gear shift fork 1 8 Locking element 1 9 Thrust plate 1 10 Loose gear wheel 4th gear 1 11 Synchroni...

Page 1288: ...complete shaft into the vice with gear set and special tool socket wrench insert 9282 2 Remove fastening nut 3 Press off loose gearwheel for 3rd gear no 20 in overview with synchronisation no 11 to 1...

Page 1289: ...the guarantee period 3 years the letter R must be imprinted after the transmission number Note Use the Damage Catalogue to diagnose the damage in the transmission top of page Tools Item Special tool...

Page 1290: ...the driver dogs B The driver dogs with spring and ball must align with the dotting marks on the shift collar 3 Check the synchronising rings for wear To do this push the synchronising rings onto the g...

Page 1291: ...3 in overview to 120 C and push onto input shaft 10 Heat cylindrical roller bearing no 2 in overview to 120 C and push onto input shaft 11 Screw new hexagon nut onto input shaft Tightening torque 250...

Page 1292: ...ring no 16 in overview the tapered ring no 15 in overview and the synchronisation ring no 14 in overview on the gear wheel no 17 in overview Measure the gap A with a feeler gauge Perform the test aga...

Page 1293: ...2nd gear side D 1st gear side 16 Fit spring no 11 in overview ball no 12 in overview and driver dog no 13 in overview To do this push the shift collar in the direction of the 2nd gear loose gearwheel...

Page 1294: ...te locking element 8 Locking element short 9 Shift rod for 1st 2nd gear 23 Fit locking elements nos 32 33 and 34 in overview Tightening torque 15 Nm 11 ftlb Note Do not move the shift rods past the ne...

Page 1295: ...torque Nm ftlb Fastening screws gear housing M 8 23 17 Screw plug M 18 x 1 5 25 19 top of page Assembling front gear set Note The overview diagram of the front gear set is provided in the chapter Disa...

Page 1296: ...e guide sleeve 8 Place synchronisation with shift fork no 26 in overview onto output shaft 9 Heat bearing inner race no 20 in overview to 120 C and place on output shaft 10 Place loose gearwheel for 5...

Page 1297: ...haft 20 Tighten new self locking nuts no 32 in overview on input shaft Tightening torque 200 Nm 148 ftlb 21 Place thrust plate no 4 in overview onto output shaft 22 Heat cylindrical roller bearing no...

Page 1298: ...nsmissions in guarantee period 3 Fill with transmission oil 34 01 55 Changing transmission oil 4 Remove transmission from assembly support and fit onto the engine 34 35 27 Removing and refitting the t...

Page 1299: ...of page Tools Item Special tool designation Remarks 1 Pressure piece 9256 2 Assembly sleeve 9255 3 Puller 9629 top of page Removing sealing ring for input shaft 1 Remove engine transmission unit and r...

Page 1300: ...be pulled off the input shaft with a wire hook if the spring should jump down when removing the sealing ring 4 Pull out sealing ring by screwing in the hexagon head screw top of page Installing sealin...

Page 1301: ...tighten the fastening screws Tightening torque 10 Nm 7 5 ftlb Note The guide tube fastening screws are micro encapsulated therefore replace screws entirely 5 Clean teeth of the input shaft and grease...

Page 1302: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tightening torques 1239...

Page 1303: ...tor lever B and locking button Note The ignition key must be in position 1 before the locking button can be pressed 2 Remove compression spring A and pull spring clip B off toward the front 3 Pull sel...

Page 1304: ...to the shift lever until it bottoms The spring clip must fully engage in the slot on the selector lever 3 Check function of locking button 996420 996421 996450 996451 996620 996621 996650 996651 einor...

Page 1305: ...emoved before starting the assembly work If the Tiptronic control module is replaced observe the points under coding the control module Coding the Tiptronic control module top of page Removing the con...

Page 1306: ...arefully pull the support up and out of the retaining points 5 Unlock and disconnect the electrical plug connection 6 Detach holder 4 7 Pull control module out of the holder and pull it out downward a...

Page 1307: ...in the electrical plug connection 2 Insert control module into the holder and engage holder 4 3 Plug in the electrical plug connection 4 Position the support and engage in lower side member einordnun...

Page 1308: ...ced If a new control module is installed the control module must adapt first Poor shifting quality can be expected therefore in the adaptation phase After the test drive let the engine run for 10 minu...

Page 1309: ...m Reset adaptation values proceed with 9 Confirm with F7 for Yes F8 for No and proceed with 10 Follow the instructions of the tester top of page Tightening torques Location Thread Tightening torque Nm...

Page 1310: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tools 1247...

Page 1311: ...ls Item Designation of the special tool Explanation Assembly sleeve 9255 top of page Removing cardan shaft Note Observe max joint angle of 20 when removing and fitting Furthermore the cardan joint mus...

Page 1312: ...es of the central shaft and remove 5 Remove bellows arrow from the central shaft top of page Installing cardan shaft Install in reverse order observing the following points 1 Always replace bellows fo...

Page 1313: ...ntil it engages in the groove C of the central shaft Check whether the bellows is seated properly by pulling on it top of page Tightening torques Location Thread Tightening torque Nm ftlb Drive shaft...

Page 1314: ...the special tool Explanation Assembly sleeve 9255 top of page Removing and installing cardan shaft Removing cardan shaft Note Observe max joint angle of 20 when removing and fitting Furthermore the ca...

Page 1315: ...splines of the central shaft and remove 5 Remove bellows arrow from the central shaft Installing cardan shaft Install in reverse order observing the following points 1 Always replace bellows for card...

Page 1316: ...ntil it engages in the groove C of the central shaft Check whether the bellows is seated properly by pulling on it top of page Tightening torques Location Thread Tightening torque Nm ftlb Drive shaft...

Page 1317: ...tening torques top of page Tools Item Designation of the special tool Remarks 1 Pressure piece Special tool pressure piece 9252 top of page Removing sealing ring for halfshaft flange Note Protect driv...

Page 1318: ...to the mounting face with special tool pressure piece 9252 2 Push in the halfshaft flange and tighten the fastening screw Tightening torque 44 Nm 32 ftlbs 3 Clip the B cable onto the air flange and mo...

Page 1319: ...on of the special tool Explanation A Striker VW 771 1 B Extraction tool VW 771 37 C Pressure piece 9252 top of page Removing and installing sealing ring for short flanged shaft Removing sealing ring f...

Page 1320: ...g 4 Undo the outer ends of both upper arms and remove the screws 5 Unscrew fastening screw for flanged shaft Figure shows removed transmission 6 Press wheel carrier downwards remove spacer ring and pu...

Page 1321: ...shaft with spacer ring 3 Check the transmission oil in the final drive and top up if necessary see Serv No 399055 top of page Tightening torques Location Thread Tightening torque Nm ftlb Wheel to whe...

Page 1322: ...tion of the special tool Explanation Torx socket wrench 9330 top of page Removing and installing long flanged shaft Removing long flanged shaft 1 Remove left rear wheel 2 Remove left drive shaft refer...

Page 1323: ...ed the flanged shaft must be carefully guided with the hand in order to prevent damage to the sealing ring in the transmission 2 Carefully insert flanged shaft into the transmission 3 Fit holder for w...

Page 1324: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tightening torques 1261...

Page 1325: ...the special tool Explanation Centering pins 9321 M8 top of page Removing the lid for front wheel drive 1 Remove the final drive Removing and installing front wheel drive 2 Drain oil 3 Press out flange...

Page 1326: ...this clamp the flange in the vice with protective jaws and press out the snap ring with the new snap ring A A New snap ring 4 Grease the snap ring well and install the halfshaft flange with the speci...

Page 1327: ...the special tool Explanation Centering pins 9321 M8 top of page Removing the lid for front wheel drive 1 Remove the final drive Removing and installing front wheel drive 2 Drain oil 3 Press out flange...

Page 1328: ...this clamp the flange in the vice with protective jaws and press out the snap ring with the new snap ring A A New snap ring 4 Grease the snap ring well and install the halfshaft flange with the speci...

Page 1329: ...Item Special tool designation Remarks Pressure piece 9537 top of page Removing the sealing ring for the flanged shaft front wheel drive 1 Remove front drive shaft 40 41 19 Removing and installing fron...

Page 1330: ...sure piece 9537 arrow up to the mounting face To do so use a rubber hammer on the centre of the pressure piece 3 Always replace the snap ring for the halfshaft flange To do this clamp the flange in th...

Page 1331: ...oil in front final drive 39 90 55 Changing oil for final drive 6 Install front drive shaft 40 41 19 Removing and installing front drive shaft 996420 996421 996450 996451 996620 996621 996650 996651 e...

Page 1332: ...Item Special tool designation Remarks Pressure piece 9537 top of page Removing the sealing ring for the flanged shaft front wheel drive 1 Remove front drive shaft 40 41 19 Removing and installing fron...

Page 1333: ...sure piece 9537 arrow up to the mounting face To do so use a rubber hammer on the centre of the pressure piece 3 Always replace the snap ring for the halfshaft flange To do this clamp the flange in th...

Page 1334: ...oil in front final drive 39 90 55 Changing oil for final drive 6 Install front drive shaft 40 41 19 Removing and installing front drive shaft 996420 996421 996450 996451 996620 996621 996650 996651 e...

Page 1335: ...Switch the engine off set the hand brake and shift the transmission to neutral 4 When the brake tester rollers have started switch the ignition on and press the Continue key of the Porsche System Test...

Page 1336: ...ont wheels in Newtons N Diagram for roller brake tester speed 4 km h A Relative measuring time in minutes B Traction at the front wheels in Newtons N Diagram for roller brake tester speed 3 km h einor...

Page 1337: ...A Relative measuring time in minutes B Traction at the front wheels in Newtons N 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Checking function of installed viscous clutch 1274...

Page 1338: ...Switch the engine off set the hand brake and shift the transmission to neutral 4 When the brake tester rollers have started switch the ignition on and press the Continue key of the Porsche System Test...

Page 1339: ...ont wheels in Newtons N Diagram for roller brake tester speed 4 km h A Relative measuring time in minutes B Traction at the front wheels in Newtons N Diagram for roller brake tester speed 3 km h einor...

Page 1340: ...A Relative measuring time in minutes B Traction at the front wheels in Newtons N 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Checking function of installed viscous clutch 1277...

Page 1341: ...the viscous clutch Installing the viscous clutch Tightening torques top of page Tools Item Designation of the special tool Explanation A Assembly aid 9638 2 parts B Holding rails VW 457 Drill two 10 5...

Page 1342: ...Removing and installing front wheel drive 3 Clamp final drive into the vice with special tool A holding rails VW 457 drain oil and remove the long neck pipe A Special tool holding rails VW 457 4 Remov...

Page 1343: ...in diagonally opposite sequence 4 Fill in oil for final drive Changing transmission oil in front wheel drive top of page Tightening torques Location Thread Tightening torque Nm ftlb Long neck pipe on...

Page 1344: ...the viscous clutch Installing the viscous clutch Tightening torques top of page Tools Item Designation of the special tool Explanation A Assembly aid 9638 2 parts B Holding rails VW 457 Drill two 10 5...

Page 1345: ...Removing and installing front wheel drive 3 Clamp final drive into the vice with special tool holding rails VW 457 drain oil and remove the long neck pipe A Special tool holding rails VW 457 4 Remove...

Page 1346: ...gonally opposite sequence 4 Fill in oil for final drive Replacing and checking transmission oil in final drive top of page Tightening torques Location Thread Tightening torque Nm ftlb Long neck pipe o...

Page 1347: ...inal drive B Fastening screws top of page Removing the support for front wheel drive 1 Remove the final drive Removing and installing front wheel drive 2 Unscrew fastening screws and remove support to...

Page 1348: ...Nm 48 ftlb 3 Install the final drive Removing and installing front wheel drive top of page Tightening torques Location Thread Tightening torque Nm ftlb Transmission support on final drive M10 65 48 9...

Page 1349: ...inal drive B Fastening screws top of page Removing the support for front wheel drive 1 Remove the final drive Removing and installing front wheel drive 2 Unscrew fastening screws and remove support to...

Page 1350: ...Nm 48 ftlb 3 Install the final drive Removing and installing front wheel drive top of page Tightening torques Location Thread Tightening torque Nm ftlb Transmission support on final drive M10 65 48 9...

Page 1351: ...insert commercially available refer to Workshop Equipment Manual Chapter 2 4 No 64 B Pressure piece 9671 C Three arm puller Commercially available refer to Technical Equipment Manual Chapter 2 4 No 1...

Page 1352: ...Degrease the pinion shaft journal splines and thread halfshaft flange splines and thread of the collar nut with cleaning agent e g Loctite quick cleaner 2 Fill the space between the dust and sealing l...

Page 1353: ...r Loctite 243 or Omnifit 50 M 6 Check transmission oil Changing transmission oil top of page Tightening torques Location Thread Tightening torque Nm ftlb Collar nut halfshaft flange M20 x 1 5 120 89 9...

Page 1354: ...ool Explanation A Socket wrench 9669 B Pressure piece 9668 C Three arm puller Commercially available refer to Technical Equipment Manual Chapter 2 4 No 112 1 D Hook VW 681 top of page Removing and ins...

Page 1355: ...o Workshop Equipment Manual Chapter 2 4 No 112 1 6 Lever off sealing ring with special tool VW 681 Installing sealing ring for cardan flange 1 Replace O ring for cardan flange 2 Fill the space between...

Page 1356: ...60 Nm 118 ftlb 4 Install cardan shaft refer to Serv No 390219 top of page Tightening torques Location Thread Tightening torque Nm ftlb Collar nut 24 x 1 5 160 118 996420 996421 996450 996451 996620 99...

Page 1357: ...ssion support rear 5 Transmission support front top of page Remove front wheel drive 1 Remove the cardan shaft Removing and installing cardan shaft 2 Remove underbody cover front 3 Remove diagonal bra...

Page 1358: ...unscrew fastening screws nuts for the rear transmission support A Pipe holder B Transmission support C Screw Note Do not undo screw C 7 Undo fastening nuts for front transmission support and unscrew...

Page 1359: ...ember and on the body top of page Tightening torques Location Thread Tightening torque Nm ftlb Studs on front axle cross member M8 20 Nm 15 ftlb Front transmission support on transmission M10 65 Nm 48...

Page 1360: ...n support rear 5 Transmission support front top of page Removing front wheel drive 1 Remove the cardan shaft 39 Removing and installing the cardan shaft 2 Remove underbody cover front 3 Remove diagona...

Page 1361: ...unscrew fastening screws nuts for the rear transmission support A Pipe holder B Transmission support C Screw Note Do not undo screw C 7 Undo fastening nuts for front transmission support and unscrew t...

Page 1362: ...member and on the body top of page Tightening torques Location Thread Tightening torque Nm ftlb Studs on front axle cross member M8 20 Nm 15 ftlb Front transmission support on transmission M10 65 Nm 4...

Page 1363: ...ening torques top of page Tools Item Designation of the special tool Explanation Filling system V A G 1924 top of page Changing transmission oil in final drive Note Use only oils approved by Porsche S...

Page 1364: ...ible on the vehicle 5 Fill in oil with special tool V A G 1924 up to the lower edge of the oil filler opening 6 To check the oil level insert a suitable object such as a bent wire into the filler open...

Page 1365: ...ing torques Location Thread Tightening torque Nm ftlb Oil drain plug M21 x 1 5 25 19 Oil filler plug M18 x 1 5 22 16 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tightening torqu...

Page 1366: ...Filling capacity approx 1 5 litres 1 Remove underbody cover front 2 Unscrew oil filler plug A 3 Unscrew the oil drain plug B and drain the oil with the vehicle horizontal 4 Clean the drain plug and f...

Page 1367: ...Location Thread Tightening torque Nm ftlb Screw plug oil drainage and oil filling M18 28 21 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tightening torques 1304...

Page 1368: ...Filling capacity approx 1 5 litres 1 Remove underbody cover front 2 Unscrew oil filler plug A 3 Unscrew the oil drain plug B and drain the oil with the vehicle horizontal 4 Clean the drain plug and f...

Page 1369: ...Location Thread Tightening torque Nm ftlb Screw plug oil drainage and oil filling M18 28 21 996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tightening torques 1306...

Page 1370: ...A Torx screwdriver 9546 To counter the ball joints track rod during assembly and disassembly B Press out tool ball joint extractor 9560 To press out the ball joint on the wheel carrier C Protective t...

Page 1371: ...ances the drive shaft must be pressed out of the toothing using a universal wheel hub extractor See step 9 also 1 Lift the vehicle Remove the wheel and undo axle nut arrow Actuate the foot brake and p...

Page 1372: ...strut arrow 8 Undo the nut on the tie rod end if necessary counter with Torx screwdriver 9546 Press the tie rod end off with a press out tool 9560 9 Disengage the parking brake cable at the parking b...

Page 1373: ...erances with a wheel hub extractor 11 Swivel the wheel carrier outwards until there is enough space for the drive shaft to be extended A second fitter is required top of page Installing the drive shaf...

Page 1374: ...ot necessary to calibrate the sensor for headlight beam adjustment only left vehicle side 1 Swivel the wheel carrier outwards until there is enough space for the drive shaft to be inserted 2 A second...

Page 1375: ...ht adjustment arrow counter with open ended wrench Only on left side 9 Mount the drive shaft on the transmission flange 10 Remove the drive shaft protection arrow 11 Tighten axle nut arrow Fasten the...

Page 1376: ...on A Torx screwdriver 9546 To counter the ball joints track rod during assembly and disassembly B Press out tool ball joint extractor 9560 To press out the ball joint on the wheel carrier C Protective...

Page 1377: ...nces the drive shaft must be pressed out of the toothing using a universal wheel hub extractor See step 9 also 1 Lift the vehicle Remove the wheel and undo axle nut arrow Actuate the foot brake and pa...

Page 1378: ...pring strut arrow 8 Undo the nut on the tie rod end if necessary counter with Torx screwdriver 9546 Press the tie rod end off with a press out tool 9560 9 Disengage the parking brake cable at the park...

Page 1379: ...nfavourable tolerances with a wheel hub extractor 11 Swivel the wheel carrier outwards until there is enough space for the drive shaft to be extended A second fitter is required top of page Installing...

Page 1380: ...t be tightened in vehicle position Vehicle position means vehicle standing on the wheels or the wheel suspension is being raised with a universal vehicle lift Use an intermediate layer hard rubber Do...

Page 1381: ...cribed in Point 8 Removal Note Always make sure that the sleeve arrow of the parking brake cable B is pushed over the parking brake cable guide tube A of the body Otherwise correct adjustment of the p...

Page 1382: ...adjustment arrow counter with open ended wrench Only on left side 9 Mount the drive shaft with spacer ring on the transmission flange 10 Remove the drive shaft protection arrow 11 Tighten the axle nu...

Page 1383: ...ge Removing front ABS lead Remove front wheel Removing and installing the wheel Turbo and GT2 Remove front wheel housing liner 6 505619 Removing and installing front wheel housing liner Remove cowl pa...

Page 1384: ...lead out of the holders arrows 4 Open the clips arrow A 5 Remove the fabric tape B and take out the lead arrow C Note When cutting off the ABS lead make sure that the length of lead in the interior i...

Page 1385: ...S lead 1 Position the socket in installation position arrow A and secure with fastening nut 1 Tightening torques 2 Insert both plugs arrow B 3 Fold back lead lock arrow C until it can be felt to engag...

Page 1386: ...imp connector and crimping tool Tools Cut off leads to different lengths due to the shrink connection Slide shrink fit hose over the leads Strip 10 mm of insulation off the leads Connect leads with cr...

Page 1387: ...t 1 for securing ABS lead to spring strut M6 9 7 7 2 top of page Tools Item Designation of special tool Remarks 1 Repair set for wiring harness 155 1 Workshop Equipment Manual Gr 2 4 996420 996421 996...

Page 1388: ...ear ABS lead Turbo GT2 Removing rear ABS lead Installing rear ABS lead Tightening torques Tools top of page Removing rear ABS lead All models Remove rear wheel Removing and 45 46 19 Removing and insta...

Page 1389: ...gency seat cushion Release rear three point belt 6 691219 Removing and installing rear three point belt Remove side panel lining 7 707519 Removing and installing side panel lining 1 Pull up carpet lin...

Page 1390: ...ent for attaching the new lead 6 Cut off the lead in area a and press inwards using the rubber sleeve b arrow Note Only for vehicles with headlight beam adjustment HBA 7 Cut through the rubber sleeve...

Page 1391: ...ess the lead into the holders by pressing on the rubber sleeves arrow Note Choose the connection point at a position with sufficient room for connecting all the individual leads The individual leads i...

Page 1392: ...the leads Strip 10 mm of insulation off the leads Connect leads with crimp connectors do not confuse colours of the individual leads Shrink shrink fit hoses with a hot air gun It is essential that al...

Page 1393: ...on Thread Tightening torque Nm ftlb Fastening nut 1 for securing ABS lead to spring strut M6 9 7 7 2 top of page Tools Item Designation of special tool Remarks 1 Repair set for wiring harness 155 1 Wo...

Page 1394: ...ake loads very high temperature fluctuations in the friction surfaces the cracking and perforating can proceed so quickly that a premature disc change has to be performed Both criteria governing accep...

Page 1395: ...he liklihood that a disc will break In the evaluation of damage the following drawings must be used A Corresponds to a disc exposed to above average load Need not be taken out of the vehicle B In part...

Page 1396: ...minimum thickness is measured in the middle of the disc effective friction radius in the case of perforated brake discs the minimum thickness must be measured on the inner or outer friction surface tr...

Page 1397: ...r profile of the previously operated brake disc than is the case with smooth brake discs In general the following applies New brake pads must be broken in bedding in period their optimum braking effec...

Page 1398: ...disc friction surfaces at advanced stage 2 Brake disc minimum thickness is not attained due to wear material erosion due to friction In practice both forms of disc erosion usually occur Only in seldom...

Page 1399: ...ary B Friction area surfaces after a long run and occasional higher load Replacement not yet necessary C End of service life of friction area surface or after highest load on a racing track Replace br...

Page 1400: ...nsion X with a suitable micrometer screw or a brake disc gauge in the area of the inner and outer friction surface traces arrow top of page 3 Checking brake discs for edge damage Note Irrespective of...

Page 1401: ...ible Use high pressure cleaning equipment to clean or expose the bores in the brake disc friction surface top of page Note on bedding in the new brake pads New brake pads require a slightly longer bed...

Page 1402: ...ads very high temperature fluctuations in the friction surfaces the cracking and perforating can proceed so quickly that a premature disc change has to be performed Both criteria governing acceptable...

Page 1403: ...liklihood that a disc will break In the evaluation of damage the following drawings must be used A Corresponds to a disc exposed to above average load Need not be taken out of the vehicle B In parts p...

Page 1404: ...minimum thickness is measured in the middle of the disc effective friction radius in the case of perforated brake discs the minimum thickness must be measured on the inner or outer friction surface tr...

Page 1405: ...r profile of the previously operated brake disc than is the case with smooth brake discs In general the following applies New brake pads must be broken in bedding in period their optimum braking effec...

Page 1406: ...surfaces at advanced stage 2 Brake disc minimum thickness is not attained due to wear material erosion due to friction In practice both forms of disc erosion usually occur Only in seldom cases for lo...

Page 1407: ...ary B Friction area surfaces after a long run and occasional higher load Replacement not yet necessary C End of service life of friction area surface or after highest load on a racing track Replace br...

Page 1408: ...nsion X with a suitable micrometer screw or a brake disc gauge in the area of the inner and outer friction surface traces arrow top of page 3 Checking brake discs for edge damage Note Irrespective of...

Page 1409: ...missible Use high pressure cleaning equipment to clean or expose the bores in the brake disc friction surface top of page Note on bedding in the new brake pads New brake pads require a slightly longer...

Page 1410: ...fitting Welding in closing panel and front floor panel Tools and materials Replacing closing panel and front floor panel The following spare body parts are required for the sectional repair Replacing...

Page 1411: ...emoved depending on the extent of the damage All straightening work on the body in this area must have been completed before the damaged parts are removed No Procedure Instructions Place vehicle on th...

Page 1412: ...middle Separate spot welded joints of the front floor panel to the bulkhead at the middle F from the inside luggage compartment side with the spotweld cutter 4 Separating spot welded joints between t...

Page 1413: ...y with a hot air gun or rotary brush 3 Fitting the front floor panel in the body and fastening it on the straightening attachments Adjust the spare front floor panel to the side members and to the bul...

Page 1414: ...under shielding gas 2 Plug welding front floor panel to the bulkhead under shielding gas Plug weld radiator tank to the front floor panel G on the left and right under shielding gas 3 Plug welding th...

Page 1415: ...3 Workshop Equipment Manual 3 Star gauges Nr 127 1 2 4 Workshop Equipment Manual 4 Shielding gas welding device 3 Workshop Equipment Manual 5 Multispot spotwelder 3 Workshop Equipment Manual 6 Pneumat...

Page 1416: ...ing front wall for installation and fitting Welding in front wall Tools and materials The following spare body parts are required for the sectional repair Replacing front wall A front wall top of page...

Page 1417: ...e followed 5 Safety notes Note The accessories in the repair area should be removed depending on the extent of the damage All straightening work on the body in this area must have been completed befor...

Page 1418: ...spot welded joints between the radiator tank and front wall Separate the spot welded joints of the radiator tank to the front wall from the inside radiator tank side C D with the spotweld cutter 3 Se...

Page 1419: ...ing with shielding gas Welding in front wall 2 Cleaning the welding areas Remove underbody coating and paint layers etc from the welding areas of the body with a hot air gun or rotary brush 3 Insertin...

Page 1420: ...er shielding gas 2 Plug welding radiator tank front wall Plug weld radiator tank to the front wall C D on the left and right 3 Welding the front wall side members under shielding gas Weld front wall a...

Page 1421: ...spot spotwelder 3 Workshop Equipment Manual 6 Pneumatic body saw 3 Workshop Equipment Manual 7 Angle grinder 3 Workshop Equipment Manual 8 Oscillating body saw special electrical cutter 3 Workshop Equ...

Page 1422: ...g wheel housing lower shell and outer side members into the body Tools and materials Replacing wheel housing bottom part and outer side member The following spare body parts are required for the repai...

Page 1423: ...depending on the extent of the damage All straightening work on the body in this area must have been completed before the damaged parts are removed No Procedure Instructions Placing vehicle on the al...

Page 1424: ...spot welded joint between lower shell wheel housing and hinge pillar Separate spot welded joint of the lower shell to the wheel housing J E and the hinge pillar I using the spotweld cutter 5 Separati...

Page 1425: ...Remove underbody coating and paint layers etc from the welding areas of the body with a hot air gun or rotary brush 3 Inserting outer side member wheel housing into the body Straightening attachment...

Page 1426: ...he body No Procedure Instructions 1 Plug welding wheel housing hinge pillar front wall and cross member under shielding gas Weld the spare wheel housing to the front wall N O with an interrupted full...

Page 1427: ...p of page Tools and materials Item Designation of the special tool Explanation 1 Basic straightening attachments for 911 Carrera 996 No 7250700 3 Workshop Equipment Manual 2 Additional straightening a...

Page 1428: ...d side members Materials and tools Partially replacing wheel housings and side members The following spare body parts are required for the sectional repair Partially replacing wheel housings and side...

Page 1429: ...les Safety instructions for welding Safety instructions for sticking Safety instructions for installation work Safety instructions for corrosion protection General information and quality notes Note A...

Page 1430: ...anel Front wall already cut out Replacing front wall 1 Removing the wheel housings Remove the damaged sections of the wheel housings B with the body saw Position the cut within the specified dimension...

Page 1431: ...the factory applied primer on the welding areas of the spare parts A B C D E F G H I with the rotary brush Drill or punch with a hole punch 7 mm holes spaced 20mm apart for plug welding under shieldin...

Page 1432: ...or the impact pipes impact absorbers and fit it in 4 Fitting in front wall Replacing front wall 5 Fitting the front floor panel in the body and fastening it on the straightening attachment Replacing c...

Page 1433: ...the alignment bench Detach side clamping jaws and straightening attachments on the vehicle Remove vehicle from the alignment bench Cleaning spot welded joints and sheetmetal flanges with a wire brush...

Page 1434: ...lating body saw special electrical cutter 3 Workshop Equipment Manual 9 Multispot spotweld cutter 3 Workshop Equipment Manual 10 Hole punch 2 4 Workshop Equipment Manual 11 Hot air gun 3 Workshop Equi...

Page 1435: ...nner side member Preparing and fitting the front inner side member for installation Welding in front inner side member Materials tools A Inner side member B Web plate top of page Removing front inner...

Page 1436: ...vehicles Safety instructions for welding Safety instructions for sticking Safety instructions for installation work Safety instructions for corrosion protection General information and quality notes...

Page 1437: ...s to be replaced Expose welding areas Remove underbody coating and paint layers etc from the welding areas of the body with the hot air gun or rotary brush Replacing closing panel Replacing closing pa...

Page 1438: ...ing areas of the body with the hot air gun or rotary brush Coat single point flange areas with zinc rich varnish All single point flange areas which will not receive a body adhesive application should...

Page 1439: ...nside passenger compartment using drill bit 7 mm top of page Welding in front inner side member Note When butt welding body sheet panels with a sheet thickness of 1 5 mm there must be a welding slit w...

Page 1440: ...ch Cleaning spot welded joints and sheetmetal flanges with a wire brush Clean spot welded joints and sheetmetal flanges with a wire brush Grind shielding gas weld area visible after installation apply...

Page 1441: ...t Manual 9 Hole punch Gr 2 4 Workshop Equipment Manual 10 Hot air gun Gr 3 Workshop Equipment Manual 11 Rotary brush Gr 3 Workshop Equipment Manual 12 Spotweld cutter 7 mm 129 Gr 2 4 Workshop Equipmen...

Page 1442: ...front water drains on Coup and Cabriolet Cleaning front water drains on Coup and Cabriolet top of page Cleaning front water drains on Coup and Cabriolet 50 93 30 Cleaning front water drains on Coup a...

Page 1443: ...d air No Procedure Instructions Removing cowl panel cover 702219 Removing and installing cowl panel cover 1 Blow out water drains on right side of front end Carefully blow out water drainage 1 from to...

Page 1444: ...of the wheel arch Remove dirt particles from the radiator tank inset B with the vacuum cleaner 4 Blow out water drainage on left side of front end Put vehicle onto platform lift and carefully blow out...

Page 1445: ...ing roof Preparation of roof for installation and fitting Welding in roof Tools and materials The following spare body parts are required for the repair Replacing roof A Roof top of page Removing roof...

Page 1446: ...r raising vehicles Safety instructions for welding Safety instructions for sticking Safety instructions for installation work Safety instructions for corrosion protection General information and quali...

Page 1447: ...of the body with the hot air gun or rotary brush 1 Separating the spot welded joints between the outer roof panel outer side section Separate the spot welded joints between the outer roof panel and th...

Page 1448: ...tting the outer roof panel Insert outer roof panel into the body Measure the dimension X 25 2 mm on the left and right of the roof channel It is necessary to measure dimension X between four corner po...

Page 1449: ...me of the adhesive The new part must be welded in within 30 minutes Otherwise the adhesion of the adhesive is impaired No Procedure Instructions 1 Applying adhesive Tools and materials Observe the wor...

Page 1450: ...with 2K primer Restore standard sealing with body sealant Paint exterior outer parts and neighbouring areas Restore standard undersealing protection with permanent undersealing protection agent Supple...

Page 1451: ...ent Manual 12 Hot air gun Gr 3 Workshop Equipment Manual 13 Rotary brush Gr 3 Workshop Equipment Manual 14 Spotweld cutter 7 mm 129 Gr 2 4 Workshop Equipment Manual 996420 996430 996431 996840 996841...

Page 1452: ...centre panel for installation and fitting Welding in the rear centre panel Tools and materials The following spare body parts are required for the repair Replacing rear centre panel A Rear centre pane...

Page 1453: ...d be removed depending on the extent of the damage All straightening work on the body in this area must have been completed before the damaged parts are removed No Procedure Instructions 1 Separate th...

Page 1454: ...the connection to the side section with the parting grinder 3 Remove the rear centre panel At the factory the rear centre panel is sealed to the convertible top rest cross member with an expanded seal...

Page 1455: ...am body gap dimensions 4 Insert seal On the inside of the new rear centre panel a sealing foam D is applied A triangular bead dimension X approx 15 mm of body sealant must be applied to the sealing fo...

Page 1456: ...ss member top A or bottom B 2 Weld the connection to the side section under shielding gas Weld the overlap of the connection to the side section with a full weld C of approx 15 mm under shielding gas...

Page 1457: ...saw special electrical cutter Gr 3 Workshop Equipment Manual 7 Multispot spotweld cutter Gr 3 Workshop Equipment Manual 8 Hole punch Gr 2 4 Workshop Equipment Manual 9 Hot air gun Gr 3 Workshop Equip...

Page 1458: ...lation of lower side member and fitting Welding in lower side member Tools and materials The following spare body parts are required for the sectional repair Replacing lower side member A lower side m...

Page 1459: ...removed depending on the extent of the damage All straightening work on the body in this area must have been completed before the damaged parts are removed No Procedure Instructions 1 Separating the...

Page 1460: ...the web plate at the top and bottom F G with the body saw 3 Separating the spot welded joint between the outer inner lower side members Separate the spot welded joint between the outer lower side mem...

Page 1461: ...tting lower side member separation point Insert outer lower side member into the body Cut through the outer lower side member overlapping at the separation point flush with the A pillar B with the bod...

Page 1462: ...illar B and the connection to the side section E with a full weld under shielding gas 2 Welding the web plate under shielding gas Weld the web plate and the inner lower side member D together with an...

Page 1463: ...Workshop Equipment Manual 5 Oscillating body saw special electrical cutter 3 Workshop Equipment Manual 6 Multispot spotweld cutter 3 Workshop Equipment Manual 7 Hole punch 2 4 Workshop Equipment Manu...

Page 1464: ...nstallation of lower side member and fitting Welding in lower side member Tools and materials The following spare body parts are required for the repair Replacing lower side member A Lower side member...

Page 1465: ...ions for welding Safety instructions for sticking Safety instructions for installation work Safety instructions for corrosion protection Note The accessories in the repair area should be removed depen...

Page 1466: ...rox 60 mm 2 Sawing through the web plate Cut through the web plate at the top and bottom F G with the body saw 3 Separating the spot welded joint between the outer inner lower side members Separate th...

Page 1467: ...with a hot air gun or rotary brush 3 Inserting outer lower side member Insert outer lower side member into the body 4 Fitting lower side member separation point Cut through the outer lower side member...

Page 1468: ...eld the connection to the side section E with a continuous full weld under shielding gas 2 Welding the web plate under shielding gas Weld the web plate and the inner lower side member D together with...

Page 1469: ...rkshop Equipment Manual 5 Oscillating body saw special electrical cutter 3 Workshop Equipment Manual 6 Multispot spotweld cutter 3 Workshop Equipment Manual 7 Hole punch 2 4 Workshop Equipment Manual...

Page 1470: ...nstalling deformation element Removing deformation element Installing deformation element top of page Removing deformation element 705719 Removing the A pillar trim 51 63 19 Removing and installing de...

Page 1471: ...cident It is impermissible to perform repairs on the deformation elements The deformation elements must be replaced in the event of visible damage or pressure marks 1 Riveting on deformation element P...

Page 1472: ...at cross member for installation and fitting Welding in seat cross member Tools and materials The following spare body parts are required for the repair Replacing seat cross member A Seat cross member...

Page 1473: ...g vehicles Safety instructions for welding Safety instructions for sticking Safety instructions for installation work Safety instructions for corrosion protection General information and quality notes...

Page 1474: ...cross member and floorpan Separate the spot weld joints between the seat cross member and the floorpan A B with the spot weld cutter 2 Separating spot welded joints between the seat cross member and i...

Page 1475: ...in seat cross member 2 Cleaning the welding areas Remove underbody coating and paint layers etc from the welding areas of the body with the hot air gun or rotary brush 3 Measuring seat cross member Me...

Page 1476: ...es C under shielding gas 3 Plug welding seat cross member under shielding gas Plug weld the seat cross member at the sides and middle D E F under shielding gas Cleaning spot welded joints and sheetmet...

Page 1477: ...Manual 2 MIG welder Gr 3 Workshop Equipment Manual 3 Pneumatic body saw Gr 3 Workshop Equipment Manual 4 Angle grinder Gr 3 Workshop Equipment Manual 5 Oscillating body saw special electrical cutter...

Page 1478: ...ing underside panel Removing and installing front cover Removing and installing middle cover Removing and installing rear trim top of page Removing and installing front cover 51 90 19 Removing and ins...

Page 1479: ...clip and press out Check if necessary replace The clip must lock with an audible click 3 Underside panel front 1 Remove from underside panel middle Insert in the middle of the underside panel 4 Expand...

Page 1480: ...emoval Installation 1 Plastic nut 10 Check if necessary replace 2 Side underside panel 1 3 Underside panel middle 1 Remove from underside panel front and rear Insert in the underside panel front and r...

Page 1481: ...4 Check if necessary replace 2 Fastening screw 6 3 Underside panel rear 1 Remove from underside panel middle Insert in the middle of the underside panel 996420 996421 996450 996451 996630 996631 9966...

Page 1482: ...ting out rear closing panel Preparing the rear closing panel for installation and fitting Welding in rear closing panel Tools and materials A closing panel top of page Cutting out rear closing panel 5...

Page 1483: ...ould be removed depending on the extent of the damage All straightening work on the body in this area must have been completed before the damaged parts are removed No Procedure Instructions Place vehi...

Page 1484: ...B C 3 Separate the spot welded joint on the engine mount at top Separate the spot welded joint between the engine mount at top D and the inner side member and the connection to the inner side section...

Page 1485: ...ush 3 Insert the closing panel into the body Insert the closing panel spare part into the body and fasten it to the straightening attachments If necessary align it with the inner side sections and the...

Page 1486: ...mbers B C and the rear closing panel on the left and right 3 Plug weld the engine mount side member at top under shielding gas Plug weld the engine mounts at the left and right to the side member at t...

Page 1487: ...3 Workshop Equipment Manual 6 Pneumatic body saw Gr 3 Workshop Equipment Manual 7 Angle grinder Gr 3 Workshop Equipment Manual 8 Oscillating body saw special electrical cutter Gr 3 Workshop Equipment...

Page 1488: ...side section Preparing side section for installation and fitting Welding in the side section Flanging the wheel arch edges GT2 Tools and materials A Side section B Seal top of page Cutting through si...

Page 1489: ...removed depending on the extent of the damage All straightening work on the body in this area must have been completed before the damaged parts are removed No Procedure Instructions 1 Separate the spo...

Page 1490: ...rim the side section at the B pillar centre with the body saw making a cut G so that the spare body part overlaps the centre of the B pillar by approx 60 mm 4 Cut through side section at C pillar Trim...

Page 1491: ...tion to the lower side section with the parting grinder 8 Separate the spot welded joint on the light housing Separate the spot welded joint between the light housing and the inside of the side sectio...

Page 1492: ...etc from the welding areas of the body with the hot air gun or rotary brush 3 Adapt the side section to the body Fit the side section to the body Insert door and rear lid to check the body contour Adj...

Page 1493: ...sing to the inside of the side section The light housing must lie flush with the side section 7 Apply adhesive to the wheel arch up to the start of the side member Apply the adhesive as a triangular b...

Page 1494: ...continuous butt weld under shielding gas 2 Weld B pillar and C pillar under shielding gas Weld B pillar H and C pillar G with a continuous butt weld under shielding gas 3 Spot weld wheel arch and low...

Page 1495: ...on small figure make sure that the welding nuts are lined up with the hole pattern in the side section Screw in M6 hexagon head bolts to position Spot weld the connection with the side section 3 7 Wel...

Page 1496: ...f necessary the rear spoiler must be reworked The wing seam must be flanged over a width of at least D 10 mm and at least E 60 never flange grind or cut off more than 65 2 Reworking rear spoiler If th...

Page 1497: ...ent Manual 12 Rotary brush Gr 3 Workshop Equipment Manual 13 Spotweld cutter 7 mm Nr 129 Gr 2 4 Workshop Equipment Manual 14 Teromix 6700 2 component adhesive Spare part Gr 8 Parts Catalogue Manufactu...

Page 1498: ...and Cabriolet Cleaning rear water drains on Coupe and Cabriolet Illustrated on the 911 Carrera Coupe and Cabriolet 996 top of page Cleaning rear water drains on Coupe and Cabriolet 53 93 30 Cleaning r...

Page 1499: ...hould be blown out carefully with compressed air The water hoses should only be blown out when the sliding tilting roof is closed No Procedure Instructions Removing side panel lining 707519 Removing r...

Page 1500: ...r drainage hose Carefully blow out the front water drainage hose in the B pillar A Rear water drainage hose Put vehicle onto lifting platform and carefully blow out the water drain A on the left and r...

Page 1501: ...and installing front emergency release as of MY 2003 Checking inner release of luggage compartment Trunk Entrapment Shown on 911 Carrera 996 55 62 19 Removing and installing front emergency release a...

Page 1502: ...1 Unclip the gripper 2 from the luggage compartment lining 1 To do so press in the locking tabs arrows Clip the gripper 2 into the luggage compartment lining 1 3 Electrical plug connection 1 Disconne...

Page 1503: ...off Stop the vehicle immediately when the warning lights light up Check whether the upper part of the lock automatically disengages from the lower part of the lock 1 Engage the upper part of the lock...

Page 1504: ...partment will impact in front of the windshield and can tear off Stop the vehicle immediately when the warning lights light up Check whether the upper part of the lock automatically disengages from th...

Page 1505: ...the cable top of page Installing engine cover release 1 Engage the cable and position the motor at the holder 2 Screw in the fastening screws Tightening torque 1 5 Nm 1 ftlb 3 Position the holder with...

Page 1506: ...Install front bumper 6 631019 Removing and installing front bumper 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Installing engine cover release 1443...

Page 1507: ...57 51 16 Setting the door 57 51 16 Setting the door 1444...

Page 1508: ...itions 5 Body gap dimensions The setting range can be extended by removing the centring sleeve 2 2 Setting the door at rear Undo fastening screw 4 Set the contour in relation to the rear wing and the...

Page 1509: ...57 51 19 Removing and installing door 57 51 19 Removing and installing door 1446...

Page 1510: ...e context of body repairs the ground strap must be disconnected No Procedure Instructions 1 Disconnecting the electrical plug connection Loosen Torx screw T20 push plug up by approx 3 mm and then pull...

Page 1511: ...nges No Procedure Instructions 1 Engaging the door up to model year 2000 Engage the door in the door hinge from above and screw in the locking screw Note the locking screw is microencapsulated and mus...

Page 1512: ...ction Attention locking tabs in the plug can break off Press in the securing latch of the plug connection B Push the whole plug connection into the A pillar Press the plug down approx 3 mm so that the...

Page 1513: ...riggered while ignition key is not removed Alway remove ignition key during body work and do not commence adjustment work until a waiting period of at least 1 minute has elapsed The ground strap of th...

Page 1514: ...the plug connection must be pulled out before the plug connection is disconnected CAUTION Danger of material damage if the door lock is installed incorrectly Malfunctions in the alarm system The door...

Page 1515: ...nnect connection piece d Move connection piece A e Press C downwards f Press the connection piece B upwards and separate from each other 4 Remove door handle and bottom part of door g Remove collar nu...

Page 1516: ...B m Pull door lock with actuating motor unit out of the door 6 Remove door window n Undo Torx screws T 30 on the clamping pieces of the power window unit o Pull door window out of the door channel 7 R...

Page 1517: ...ove the seal 9 Remove door seal on outside w Press out clip A with a plastic spatula x Pull off door seal on the outside y Carefully pull the seal out of the clips along the door contour 10 Remove win...

Page 1518: ...and the 20 x 28 lid B with a plastic spatula 13 Remove wiring harness ab Unclip the electrical wiring along the inner door panel ac Pull wiring harness out of the door in the direction of the arrow 14...

Page 1519: ...nd alignment bench work within the framework of body repair Note Follow the special instructions on installation and adjustment for assembly of the door 1 Stick in the insulation Note In order to achi...

Page 1520: ...the electrical wiring along the inner door panel 4 Fit lid Press in the 24 x 40 lid A and the 20 x 28 lid B 5 Fit door channel seal on inside Position the door channel seal on the inside arrow in the...

Page 1521: ...the top edge of the door and push it on e Clip in the seal along the door contour f Fasten the door seal on the inner door panel with the clip A 8 Fit door brake g Position the seal h Insert door brak...

Page 1522: ...ower window unit Note The bottom edge of the window must rest on the screw during adjustment Observe additional instructions for adjusting the door window n Tighten the T 30 Torx screw Tightening torq...

Page 1523: ...nection A 13 Disconnect connection piece t Insert the connection piece into the actuating shaft arrow A without play u Push out the sliding piece arrow B until it can be heard to engage v Actuate the...

Page 1524: ...mount Position the mount in the door and fasten it with the M6 x 16 hexagon head bolt Tightening torque 10 Nm 7 5 ftlb 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Assembling doo...

Page 1525: ...in the clamping jaws Adjusting the door window angle in the vehicle s longitudinal direction Adjusting the door window height Adjustment of the door window pressing force on the door seal at the top a...

Page 1526: ...tal clip D Grommet E Sheetmetal clip St 3 8 top of page Basic setting of door lock WARNING Danger of injury if side airbag units in the door are triggered while ignition key is not removed einordnung...

Page 1527: ...Malfunctions in the alarm system The door lock should be installed only when the actuating lever is in basic position 1 Swivel out the actuating lever A in an upward direction 2 Lift the spring and s...

Page 1528: ...ow is closed and is switched off by the blockage detection function of the power windows Blockage detection function Note If the window drive encounters resistance during the door window movement the...

Page 1529: ...indow on the clamping jaws of the driver upwards or downwards Adjustment range 10 mm 2 Tighten the clamping jaw after completing the adjustment top of page Adjusting the door window height 1 Adjust th...

Page 1530: ...at the door window evenly projects approx 2 mm above the roof strip Checking the adjustment 1 Close the doors 2 Use a wax marker to mark the door window along the roof strip 3 Actuate the door handle...

Page 1531: ...s upper position and undo the combination nuts M 6 of the power window rails 3 Adjust the power window unit so that the upper edge of the door window is sufficiently pressed against the door seal at t...

Page 1532: ...respective model There are two bores lying one above the other with the screwed on limit stops in the front power window unit rail The upper limit stop must be removed for the 911 Carrera 996 model 9...

Page 1533: ...window section for installation Preparing the windscreen for installation Fitting windscreen Overview of tools and materials top of page Removing windscreen WARNING Danger of cut injuries when removin...

Page 1534: ...emoving and installing cowl panel cover 2 Removing inner A pillar trim 705719 Removing and installing trim of A B and C pillars 3 Removing interior rearview mirror 682719 Removing and installing inter...

Page 1535: ...cer blocks 6 and remove the expanding rivets Spacer blocks 6 must be replaced 9 Removing windscreen Remove windscreen with the cutting wire separator Note The procedure for removing car windows is des...

Page 1536: ...riming paint damage or newly built up paint areas in the window aperture of the body Clean new paint areas or damage to the top coat paint in the non visible area of the glass section in the body with...

Page 1537: ...g adhesive helps new adhesive to stick Keep cut surfaces clean and free of grease and do not clean with cleaning solution 2 Fitting surrounding section and cover section Place surrounding section 9 on...

Page 1538: ...e periods apply activator H3 to the remaining adhesive Note Only with new windscreens a Clean glass with cleaning solution H1 b Apply primer H2 to the glass flange in the area of the marking Note A ve...

Page 1539: ...ess light Check the fastening clips 5 replace if necessary Insert the defroster covers left and right 3 and 4 and clip in under the alarm readiness lug Clip in alarm readiness light 2 3 Preparing 2 co...

Page 1540: ...Inserting windscreen into the body Note Two persons are needed to insert and adjust the windscreen Apply suction cups B to the windscreen and insert the windscreen into the window aperture Press the w...

Page 1541: ...interior rearview mirror 11 Installing interior rearview mirror 682719 Removing and installing interior rearview mirror Note The interior rearview mirror may only be installed after a curing time of...

Page 1542: ...e VAG 1561 A See Workshop Equipment Manual Chapter 3 5 D Flashing knife U type 639 031 130 22 H 2 component window bonding agent 000 043 300 94 Contains set components H1 H8 Item Designation Item Desi...

Page 1543: ...ng thread See Parts Catalogue in Main Group 8 Item Designation Item Designation A1 Guide rails A6 Filler A2 Cutting tool wire holder A7 Steering roller with arm bracket A3 Spooling device A8 Handle A4...

Page 1544: ...f the door near the power window motor and the loudspeaker cut out See also 705919 Removing and installing door trim panel 3 Loosen the three fastening nuts arrows from the power window motor 4 Press...

Page 1545: ...by continuously actuating the power window operating button and then close window Press power window button until the window is closed and is switched off by the blockage detection function of the po...

Page 1546: ...wer windows Cabriolet Installing rear power windows Cabriolet Additional instructions for adjusting or replacing the rear power window Tools and materials Tightening torques Test and adjusting values...

Page 1547: ...d be carried out with a rear window pane Otherwise adjustment work is hindered during installation 1 Removing side panel lining Removing side panel lining 1 70 75 19 2 Removing rear side window inner...

Page 1548: ...er be electrically operated when the convertible top support is detached No Procedure Instructions 5 Detaching convertible top support Undo fastening screws 2 and fastening nuts 8 from the convertible...

Page 1549: ...top support 10 and tighten Tightening torque 23 Nm 17 ftlb Insert the deflection fitting in the belt guide section 9 Screw in and tighten the fastening screws 2 Tightening torque 50 Nm 37 ftlb 3 4 Ad...

Page 1550: ...f the convertible top is closed the ignition is switched on after the ignition is switched off if the ignition key is not removed from the steering lock after the ignition is switched off until a door...

Page 1551: ...support 2 8 M8 23 17 Fastening screw for tightening the deflection fitting in the belt guide section M8 50 37 Adjusting elements of the door window A B 23 17 top of page Test and adjusting values Desi...

Page 1552: ...Removing and installing side window Removing side window Installing side window Test and adjusting values Tightening torques top of page Removing side window 64 75 19 Removing and installing side win...

Page 1553: ...ening screw 1 and remove the washer 2 Unscrew fastening nuts 3 2 Remove side window Pull out side windows 4 downward in in direction of arrow 3 Pull off the rubber seal Pull off rubber seal 5 from the...

Page 1554: ...reinstalled if there is no prior damage to the side window the side window was removed without being damaged No Procedure Instructions 1 Fitting the rubber seal Fit the rubber seal 5 on the rim of the...

Page 1555: ...values 4 Unscrew fastening nuts and screws Screw down the fastening screw 1 and washer 2 Screw down the fastening nuts 3 Tightening torque Tightening torques Install B and C pillars 705719 Install tr...

Page 1556: ...op of page Installing side window 1 Installing the side window in the clamping jaws The convertible top must be open to fit the side window The power window must be in the upper position Insert the si...

Page 1557: ...n the side window is lowered top of page Tightening torques Location Illustration Thread Tightening torque Nm ftlb Clamping jaws for installing the side windows 8 5 6 5 1 5 1 top of page Test and adju...

Page 1558: ...Removing and installing side window seal Removing side window seal Installing side window seal Materials and tools top of page Removing side window seal 64 76 19 Removing and installing side window s...

Page 1559: ...p of the side window seal 1 using a 4 1 mm drill bit Pull out the side window seal 1 in the direction of the arrow from the retaining strip 2 2 Boring out side window seal Bore out the pop rivets 3 fr...

Page 1560: ...he retaining strip Removing the retaining strip Using a 4 1 mm drill bit bore out the pop rivets 3 from the retaining strip 2 top of page Installing side window seal einordnung Removing the retaining...

Page 1561: ...aining strip 2 with soapy water Insert the side window seal 1 in the retaining strip 2 3 Fitting the side window seal in the retaining strip Starting from the rear fit the side window seal 1 in the di...

Page 1562: ...the retaining strip press toward the rear in the direction of arrow Then rivet down all pop rivets top of page Materials and tools Item Special tool designation Remarks 1 Fitting roller 163 1 For fit...

Page 1563: ...oving rear power windows Cabriolet Pull side window seal down and out of the window profile top of page Installing side window seal Remove adhesive residues from above and below the window profile if...

Page 1564: ...briolet Removing rear glass window of Cabriolet Installing rear glass window of Cabriolet Tools and materials Shown on 911 Carrera 996 top of page Removing rear glass window of Cabriolet 64 86 19 Remo...

Page 1565: ...p covering when replacing the convertible top covering No Procedure Instructions Removing roof lining at the front at rear 708419 Removing and installing Cabriolet roof lining as of model year 2002 1...

Page 1566: ...metal clips Insert a plastic spatula direction of arrow A underneath the metal clip 7 and lift Press out the metal clip using a screwdriver direction of arrow B 4 Taking off rear window Remove the re...

Page 1567: ...s F of the rear window Tools and materials Use of the circlip pliers 3 Installing rear roof lining Push in the connection seal 10 of the roof lining 9 between the rear window and the frame Ensure that...

Page 1568: ...ches No 127 2 for holding the rear window on the convertible top covering Commercially available tools Gr 2 4 Workshop Equipment Manual Use of the circlip pliers 1 Inserting metal clips into the circl...

Page 1569: ...screw knurled screw 11 Pull upper adjusting claw Y to the right in direction of arrow d Push circlip pliers to the front direction of arrow and remove from the U profile of the lower jaw A e Pull the...

Page 1570: ...ndow hardtop Preparing the window section hardtop for installation Preparing the rear window hardtop for installation Installing rear window hardtop Overview of tools and materials Tightening torques...

Page 1571: ...utting out car windows Only replace the cutting knife with the power supply disconnected in order to avoid the cutter being switched on accidentally 1 Removing hardtop Unlock hardtop and take it off t...

Page 1572: ...l 6 on the roof liner 7 to the rear and detach it 7 Disconnecting the plug connection of the rear window heater Disconnect electrical plug connection 8 to the left and right on the rear window Note To...

Page 1573: ...the cutter C Set the vibration frequency controller to 5 Cut through the bond between the body and the rear window at the top bottom and sides Note When cutting out the rear window take care not to da...

Page 1574: ...ch as possible without damaging the rivet connections 2 Cleaning and priming paint damage or newly built up paint areas in the window aperture of the hardtop body Clean new paint areas or damage to th...

Page 1575: ...sive remains Note The remaining adhesive helps new adhesive to stick Keep cut surfaces clean and free of grease and do not clean with cleaning solution 2 Applying activator to the bonding section of t...

Page 1576: ...the curing time has elapsed In order to ensure that the bonded joint is sufficiently strong the following boundary conditions must be adhered to Curing time 3 hours Temperature at least 10 C Fixing t...

Page 1577: ...m long adhesive bead of fresh adhesive to a piece of cardboard before processing 3 Applying adhesive to the rear window Apply 2 component bonding material with the adhesive gun A to the rear window al...

Page 1578: ...oing so Use adhesive tape to prevent the rear window from slipping at the side and the top 6 Cleaning fields of vision Adhesive which has oozed out must be removed immediately and the affected fields...

Page 1579: ...rim 3 on the left and right 12 Fitting centring pegs Insert right and left centring pegs 2 screw in fastening screw 1 and tighten to the specified torque Tightening torques 13 Installing hardtop Place...

Page 1580: ...31 130 22 E Cutting knife U type 639 030 760 12 H 2 component window bonding agent 000 043 300 94 Contains set components H1 H8 Item Designation Item Designation H1 Cleaning solution H5 Cartridge comp...

Page 1581: ...996630 996631 996620 996621 996650 996651 einordnung Tightening torques 1518...

Page 1582: ...66 31 19 Removing and installing sill cover Removing sill cover Installing sill cover top of page Removing sill cover 66 31 19 Removing and installing sill cover 1519...

Page 1583: ...from the rear wheel housing liner 4 3 Undoing sill cover on the lower side member Unscrew fastening screws 2 along the sill cover 1 4 Removing sill cover from the lower side member Remove sill cover f...

Page 1584: ...s are to be replaced before installing the sill cover 1 Spray grommets with a lubricant e g silicone spray for simplified mounting of the sill pegs 5 3 Fitting sill cover Position sill cover 1 on the...

Page 1585: ...ing in front sill cover Tighten front sill cover and the front wheel housing liner 4 using the fastening screws 2 996420 996421 996450 996451 996840 996841 996430 996431 einordnung Installing sill cov...

Page 1586: ...oving pump Filling the pump unit Installing pump Bleeding the pump unit Removing and installing wiring harness Troubleshooting Tools and materials Note The hydraulic lines banjo bolts and the sealing...

Page 1587: ...top of page Removing hydraulic cylinder einordnung Removing hydraulic cylinder 1524...

Page 1588: ...embled the pump motor must be moved to its lower initial position Move pump unit into lower initial position To do this connect narrow contact to 12 V wide contact ground to the pump motor according t...

Page 1589: ...n open ended wrench C Disconnecting hydraulic lines from the pump unit Removing pump top of page Filling the hydraulic cylinder 1 Filling the hydraulic cylinder The hydraulic cylinder can only be fill...

Page 1590: ...motor must be extended and retracted Installing pump 1 Fitting short hydraulic line 4 Fit short hydraulic line 4 with the sealing rings 6 Screw in short banjo bolt 1 2 Fitting long hydraulic line 5 F...

Page 1591: ...inder 2 Bleeding the pump unit Bleeding the pump unit top of page Removing pump No Procedure Instructions Removing pump unit 559037 Disassembling and assembling rear lid Installing hydraulic cylinder...

Page 1592: ...lling the pump unit 1 Filling the pump unit a Fill the pump vertically using a syringe with 20 ml Pentosin per pump chamber Tools and materials Only Pentosin CHF 11 S may be filled into the pump unit...

Page 1593: ...rew in banjo bolt 3 and tighten slightly Tightening torque 1 Nm 0 5 ftlb 2 Fitting long hydraulic line Lay long hydraulic line 5 along the pump unit arrow B position the sealing rings 6 Screw in banjo...

Page 1594: ...lower initial position To do this connect wide contact to ground narrow contact 12 V to the pump motor according to the polarisation arrangement A 5 To avoid oil leaking out hold the hydraulic lines...

Page 1595: ...nical stop inset X push back onto the stop if necessary hydraulic lines must be laid parallel to eachother inset Z Tighten banjo bolt 3 Tightening torque 15 Nm 11 ftlb 3 Bleeding long hydraulic line S...

Page 1596: ...iring harness Removing wiring harness No Procedure Instructions 1 Hydraulic cylinder right Loosen fastening screws on right hydraulic cylinder Unscrew 2 fastening screws 3 Screw can remain installed 2...

Page 1597: ...plug connections for fan and engine compartment lighting on the fan housing Unscrew fastening screws 7 and remove fan with fan housing 6 6 Disconnecting mount 8 Unscrew fastening screws 9 Remove moun...

Page 1598: ...ghtening torque 10 Nm 7 5 ftlb 3 Installing fan with fan housing 6 Put on fan with fan housing 6 and tighten with the three fastening screws 7 Tightening torque 10 Nm 7 5 ftlb Push on plug for fan and...

Page 1599: ...ar spoiler is controlled via the instrument cluster The micro switches can be checked with the Porsche System Tester The micro switches are located on the right hydraulic cylinder The operating princi...

Page 1600: ...dual wires Shrink shrink fit hoses with a hot air gun It is essential that all wires are watertight Wrap commercially available PVC tape all around the area of the connection points 4 Position holder...

Page 1601: ...eeding the pump unit top of page Tools and materials Item Designation of the special tool Explanation 1 Pentosin CHF 11 S For filling the pump unit and the hydraulic cylinder Spare part Gr 4 Parts Cat...

Page 1602: ...c cylinder The operating principle of the micro switches differs NO or NC contacts top of page Remove micro switches 1 Unscrew fastening screws 2 for holder micro switch 1 on the right hydraulic cylin...

Page 1603: ...leads Strip 10 mm of insulation off the wires Connect wires with crimp connectors do not confuse colours of the individual wires Shrink shrink fit hoses with a hot air gun It is essential that all wir...

Page 1604: ...mbling and assembling the rearview mirror Disassembling the rearview mirror Assembling the rearview mirror top of page Disassembling the rearview mirror 66 89 37 Disassembling and assembling the rearv...

Page 1605: ...efully pull the rearview mirror glass 2 out of the metal clips Disconnect electrical plug connection 3 3 Removing the rearview mirror shell Unscrew fastening screws 4 from the rearview mirror shell 1...

Page 1606: ...ositioning motor Unscrew fastening screw 6 from the positioning motor 7 Disconnect electrical plug connection 8 7 Removing the metal clip Unscrew fastening screw 10 from the metal clip 11 and the reta...

Page 1607: ...ening screws 10 2 Installing positioning motor Plug in electrical plug connection 8 Position the positioning motor 7 on the retaining bracket and screw down using the fastening screws 6 3 Installing c...

Page 1608: ...the rearview mirror shell Secure the rearview mirror shell 1 with the fastening screws 4 6 Installing the rearview mirror glass Plug in electrical plug connection 3 Insert rearview mirror glass 2 int...

Page 1609: ...68 05 19 Removing and installing inner sill driver s side Removing inner sill Installing inner sill top of page Removing inner sill 68 05 19 Removing and installing inner sill driver s side 1546...

Page 1610: ...pwards out of the bottom support with a plastic spatula and press out Check fastening clips 4 replace if necessary 3 Pulling off plug connections 5 6 of the actuating switches Pull off plug connection...

Page 1611: ...rear lid Push plug connections 5 6 onto the actuating switches of the lids 2 Putting on sill cover 1 Clip in new fastening clips 4 if necessary Insert sill cover 1 downward into the lower support and...

Page 1612: ...996420 996421 996450 996451 996840 996841 996430 996431 einordnung Installing inner sill 1549...

Page 1613: ...68 05 19 Removing and installing inner sill passenger s side Removing inner sill Installing inner sill top of page Removing inner sill 68 05 19 Removing and installing inner sill passenger s side 1550...

Page 1614: ...f the odmments tray and unscrew the fastening screws 3 from the sill 2 Removing sill 1 Lift sill 1 upwards out of the bottom support with a plastic spatula and press out Check fastening clips 4 replac...

Page 1615: ...ng clips 4 if necessary Insert sill 1 downward into the lower support and engage 2 Fastening sill 2 Screw in fastening screws 3 and lay rubber mat 2 into the oddments tray 996420 996421 996450 996451...

Page 1616: ...moving and installing glove compartment lock Removing and installing glove compartment lock top of page Removing and installing glove compartment lock 68 11 19 Removing and installing glove compartmen...

Page 1617: ...ck for the glove compartment can not be removed from the handle 3 Handle with lock for glove compartment 1 Remove lock for glove compartment 3 from the glove compartment lid Position the lock for the...

Page 1618: ...artment Installing lid for glove compartment Replacing microswitch and interior light Replacing pneumatic shock absorber A Lid for glove compartment B Pneumatic shock absorber top of page Removing lid...

Page 1619: ...he front fastening screws Unscrew front fastening screws 1 2 Unscrewing fastening screws at the side Unscrew fastening screws 1 at the side top of page Installing lid for glove compartment einordnung...

Page 1620: ...2 to the left and right and replace if necessary 1 Screwing in the front fastening screws Screw in front fastening screws 1 2 Screwing in fastening screws at the side Screw in fastening screws 1 at th...

Page 1621: ...connect the electrical plug connection 2 Installing microswitch and interior light d Plug in the electrical plug connection of the interior light 1 Press the interior light 1 into the cut out of the g...

Page 1622: ...out of the glove compartment 2 Installing the pneumatic shock absorber Insert the pneumatic shock absorber 1 and turn it 90 clockwise in the direction of arrow A Insert the pneumatic shock absorber i...

Page 1623: ...8 15 19 Removing and installing glove compartment Removing glove compartment Installing glove compartment top of page Removing glove compartment 68 15 19 Removing and installing glove compartment 1560...

Page 1624: ...om the glove compartment 3 Unscrewing the front fastening screws Unscrew fastening screws 4 from the glove compartment 4 Disconnecting the electrical plug connection Disconnect the electrical plug con...

Page 1625: ...t into the dashboard in the direction of the arrow Note the position of the locating peg A 3 Screwing in the front fastening screws Screw in the fastening screws 4 in the glove compartment Tightening...

Page 1626: ...aking sure that the corners are inserted correctly under the dashboard Press in plastic clips 2 996420 996421 996450 996451 996620 996621 996650 996651 996430 996431 996630 996631 einordnung Installin...

Page 1627: ...68 17 19 Removing and installing center console front section 68 17 19 Removing and installing center console front section 1564...

Page 1628: ...laterally into the clips 3 2 Cover front right 1 Unclip the front right cover 2 at the sides Position the front cover 2 on the front centre console 15 and clip it laterally into the clips 3 3 Clip 10...

Page 1629: ...CD drive for navigation 1 See 911219 Removing and installing navigation unit CD drive 11 Heating air conditioning control 1 See 870219 Removing and installing the heating air conditioning control 12 F...

Page 1630: ...ws 5 16 Plug in nut 4 Inspect and replace if necessary 17 Collar nut 4 Tightening torque 10 Nm 7 5 ftlb 18 Holder 1 996420 996421 996450 996451 996840 996841 996430 996431 einordnung 68 17 19 Removing...

Page 1631: ...68 17 19 Removing and installing center console 68 17 19 Removing and installing center console 1568...

Page 1632: ...ction No Designation Qty Removal Installation 1 Shift lever knob 1 Disengage from the clips 2 all the way round Pull the shift lever knob 1 upwards and out Push on 2 Clip 4 Inspect and replace if nece...

Page 1633: ...astening screws 3 7 Rubber insert 1 8 Floor oddments tray 1 Undo fastening screw 3 from the floor oddments tray 8 Position the floor oddments tray 8 in the centre console and fasten with the fastening...

Page 1634: ...68 30 19 Removing and installing cup holder Removing cup holder Installing cup holder top of page Removing cup holder 68 30 19 Removing and installing cup holder 1571...

Page 1635: ...ning bracket 3 top of page Installing cup holder 1 Installing cup holder Push cup holder 2 into the shaft of the retaining bracket 3 Make sure that the metal clip 1 engages 701837 Installing cover and...

Page 1636: ...ving and installing front three point belt Removing front three point belt Installing front three point belt top of page Removing front three point belt 69 11 19 Removing and installing front three po...

Page 1637: ...s out the covering cap 1 with a screwdriver Unscrew fastening screw 2 Remove the seat belt with fitting 4 and spacer sleeve 5 Removing belt tensioner Only on vehicles with belt tensioner Removing belt...

Page 1638: ...with belt tensioner Installing belt tensioner Removing belt tensioner 1 Installing deflector Position the deflector and the seat belt on the inner side section and screw tight with the fastening screw...

Page 1639: ...sure that the belt strap can run properly Screw the fastening screw 2 the seat belt with fitting 3 and the spacer sleeve 5 tight on the inner lower side member Tightening torque 50 Nm 37 ftlb Removing...

Page 1640: ...nstalling front three point belt Cabriolet Removing front three point belt Installing front three point belt top of page Removing front three point belt 69 11 19 Removing and installing front three po...

Page 1641: ...r sleeve 5 Removing side panel lining Removing side panel lining 707519 2 Removing deflector Unscrew fastening screws 6 from the deflector 7 Removing belt tensioner Only on vehicles with belt tensione...

Page 1642: ...elt device 9 Make sure that the locking tab arrow of the automatic belt device is engaged correctly in the sheetmetal bracket 8 Tightening torque 50 Nm 37 ftlb 2 Installing deflector Position the defl...

Page 1643: ...hat the belt strap can run properly Screw the fastening screw 2 the seat belt with fitting 3 and the spacer sleeve 5 tight on the inner lower side member and press in the covering cap 1 Tightening tor...

Page 1644: ...t system must be replaced Test points Checking belt strap Checking automatic belt device locking effect Belt buckle visual inspection Belt buckle function test Checking sash guides Checking mounting e...

Page 1645: ...age type 4 The belt tensioner must always be replaced if it has been triggered The seat belt is damaged by the deflector Figure 4 top of page Checking automatic belt device locking effect The automati...

Page 1646: ...buckle visual inspection Inspect the belt buckle for crack formation and flaking In the case of damage the entire seat belt and belt buckle must be replaced top of page Belt buckle function test Check...

Page 1647: ...amage the entire seat belt and belt buckle must be replaced top of page Checking mounting elements and mounting points Check the belt buckle strap for distortion Check the function of the height adjus...

Page 1648: ...moving and installing rear three point belt Removing rear three point belt Installing rear three point belt top of page Removing rear three point belt 69 12 19 Removing and installing rear three point...

Page 1649: ...ng screw 3 from the automatic belt device 4 2 Removing seat belt and fitting Press out the covering cap 5 with a screwdriver Unscrew fastening screw 6 Remove the seat belt with fitting 7 and spacer sl...

Page 1650: ...s on 3 Removing seat belt and fitting Make sure that the belt strap can run properly Screw the fastening screw 6 washer 5 seat belt with fitting 7 and the spacer sleeve 8 tight on the inner lower side...

Page 1651: ...g B pillar trim 705719 Removing and installing trim of A B and C pillars Removing side panel lining 707519 Removing and installing wheel trim 996420 996421 996450 996451 996840 996841 996430 996431 ei...

Page 1652: ...installing rear three point belt Cabriolet Removing rear three point belt Installing rear three point belt top of page Removing rear three point belt 69 12 19 Removing and installing rear three point...

Page 1653: ...s and out 2 Removing belt buckle Press out the cover 2 with a plastic spatula Unscrew the fastening screw 3 from the metal clip 4 and the belt buckle 5 3 Removing seat belt and fitting Press out the c...

Page 1654: ...row of the automatic belt device is engaged correctly in the sheetmetal bracket and screw down with the fastening screw 2 B Tightening torque 50 Nm 37 ftlb 2 Installing seat belt and fitting Make sure...

Page 1655: ...l with the fastening screw 9 and press in the cover 10 Tightening torque 50 Nm 37 ftlb 4 Installing seat cushion Press the seat cushion 11 on to the Velcro fastenings Installing the rear wall lining a...

Page 1656: ...e As from model year 2002 the front three point belts in the 911 Turbo 996 will contain belt tensioners as standard After the belt tensioners have been triggered they must be replaced The triggering c...

Page 1657: ...nsioner with a screwdriver in the direction of the arrow 3 Pull the plug A out of the belt tensioner arrow 4 Unscrew the fastening screw B and remove the belt tensioner top of page Installing belt ten...

Page 1658: ...on the belt arrow 1 check the winding ability of the belt strap 6 Read out the fault memory with the Porsche System Tester Removing and installing front three point belt 996420 996421 996450 996451 99...

Page 1659: ...t fitting seat belt height adjuster Removing and installing adjustment fitting Illustrated on Targa 996 top of page Removing and installing adjustment fitting 69 36 19 Removing and installing adjustme...

Page 1660: ...hten Tightening torque 23 Nm 17 ftlb 2 Adjustment fitting 1 Guide the adjustment fitting 2 upwards out of the B pillar in the direction of the arrow Insert the adjustment fitting 2 downwards into the...

Page 1661: ...ag Install sensor for side airbag Tools top of page Remove sensor for side airbag Note Sensors for triggering the side airbag unit are fastened on the inner lower side member on the left and right han...

Page 1662: ...Removing and installing front seat Remove the side lining at rear 7 707519 Removing and installing side panel lining Remove sill 6 680519 Removing and installing the sill 1 Disengage floor covering at...

Page 1663: ...age Install sensor for side airbag 1 Position sensor and secure with the fastening screws Tightening torque 10 Nm 7 5 ftlb 2 Connect electrical plug connection 3 Position the support and engage in low...

Page 1664: ...ny faults present in the POSIP menu and erase 0 69 01 Diagnosis troubleshooting airbag Insert sill 6 680519 Removing and installing the sill Mount the side lining at rear 7 707519 Removing and install...

Page 1665: ...moving roll over protection system Installing roll over protection system Tightening torques top of page Safety instructions for work on the roll over protection system It is impermissible to perform...

Page 1666: ...over protection system must be tested by triggering it via the diagnostic interface of the Porsche System Tester Perform the function test on the roll over protection system only with the hardtop and...

Page 1667: ...roll over bar modules only after the roll over bar has been extended triggered No Procedure Instructions 1 Removing rear wall lining Remove fastening screws 1 from the rear wall lining 2 on the left...

Page 1668: ...the diagnostic socket Switch on ignition Select menu item Roll over protection Select menu item Drive links in the command line which then appears Press the key combination described in the Tester the...

Page 1669: ...torque 33 Nm 24 ftlb 3 Nm 2 ftlb 3 Triggering roll over protection system with the Porsche System Tester 2 Test the roll over protection system 5 function test Select menu item Roll over protection S...

Page 1670: ...rd and press in the roll over bar until it can be felt to engage Fit cover flaps 3 on the left and right 6 Fitting rear wall lining Position rear wall lining 2 on the auxiliary frame and fasten it on...

Page 1671: ...sing a support tool support the trim and unscrew and remove the plastic screw from the control module cover 7 Disconnect the electrical plug connection Undo the shear off nuts with socket wrench inser...

Page 1672: ...er 2 refer to Group 01 Entire vehicle General Sales check Deactivating the transport lock in the roll over protection system 911 Cabriolet top of page Tools and materials Item Special tool designation...

Page 1673: ...r protection system Removing and installing frame for roll over protection system Tightening torques top of page Removing and installing frame for roll over protection system 69 77 19 Removing and ins...

Page 1674: ...and lift frame 3 out of the vehicle Position frame in the vehicle Dimension X 491 1 mm Measure centre of screwed point convertible top support side section on inside to frame cutout on right and left...

Page 1675: ...drive 1 24 Fastening nut 4 Tightening torques top of page Tightening torques Location Illustration Thread Tightening torque Nm ftlb Hexagon head bolts for installing the roll over bar 1 M10 65 48 6 4...

Page 1676: ...t luggage compartment trim Removing and installing trims units Removing and installing carpet lining Tools and materials top of page Removing and installing trims units 70 05 19 Removing and installin...

Page 1677: ...remove Position and turn 90 2 Interior light 1 Press out Press in 3 Fastening screws 3 Unscrew Screw in 4 Trim units 1 Unscrew fastening screws 3 Screw in fastening screws 3 5 Holder 2 6 Holder 2 top...

Page 1678: ...1 Plug 4 Removal tool Tools and materials Press in 2 Short plastic nuts 1 Unscrew Screw in 3 Cover cap 2 4 Fastening screw 1 Unscrew Screw in 5 Panel 1 6 Front carpet lining 2 7 Rear carpet lining 2 8...

Page 1679: ...Tools and materials Item Special tool designation Remarks 1 Removal tool universal no 21 Gr 2 4 Workshop Equipment Manual 996430 996431 996630 996631 996420 996421 996450 996451 996620 996621 996650 9...

Page 1680: ...t as of model year 2003 Removing and installing the instrument panel Removing and installing the instrument panel bracket Tightening torque Tools and materials top of page 70 18 19 Removing and instal...

Page 1681: ...embling the instrument panel No Designation Qty Removal Installation 1 Fastening screws 3 Unscrew fastening screws 1 from the instrument panel 4 Screw the instrument panel 4 to the instrument panel br...

Page 1682: ...rument panel 1 See Position 1 and 2 See Position 1 and 2 5 Sheetmetal nut 2 Unscrew the fastening screws 2 Inspect and replace if necessary 6 Instrument panel bracket with knee protector strip 1 7 She...

Page 1683: ...strument panel bracket No Designation Qty Removal Installation 2 Fastening screws 4 7 Sheetmetal nut 4 8 Fastening screws 4 Tightening torque 9 Threaded plate 4 It is screwed into position with the co...

Page 1684: ...tening screw 15 16B USA version knee protector strip 1 Unscrew fastening screws 15 from the knee protector strip 16B Remove the knee protector strip Secure the knee protector strip 16B on the instrume...

Page 1685: ...l panel fastening screws on the instrument panel bracket 11 M6 10 7 5 Nm ftlb Knee protector strip fastening nuts on the instrument panel bracket 14 M6 10 7 5 Nm ftlb Knee protector fastening screws o...

Page 1686: ...1 Socket wrench insert 9259 Gr 2 2 Workshop Equipment Manual 2 Adhesive pad commercially available Teflon adhesive tape Cutting with adhesive pad 996420 996421 996450 996451 996840 996841 996430 99643...

Page 1687: ...70 41 19 Removing and installing floor covering 70 41 19 Removing and installing floor covering 1624...

Page 1688: ...installing centre console front section 691119 Removing and installing front three point belt No Designation Qty Removal Installation 1 Plastic cover 1 Pull off plastic cover of the handle hole Attac...

Page 1689: ...lling inner sill 551037 Disassembling and assembling release for lid 680519 Removing and installing inner sill Insert floor covering 11 in the cutout for the lid release 10 or inner sill See Section B...

Page 1690: ...m of A B and C pillars Removing and installing trim of A B and C pillars Installing trim of A B and C pillars top of page Removing and installing trim of A B and C pillars 70 57 19 Removing and instal...

Page 1691: ...lease 3 out of the hexagon head bolt 4 using a screwdriver 3 Removing B pillar trim Undo hexagon head bolt 4 of the sash guide mount 5 Undo fastening screw 6 Lift up B pillar trim 7 and remove 4 Uncli...

Page 1692: ...rim 11 at the side of the windscreen frame transition point to dashboard clip in the A pillar trim along the roof frame 2 Clipping in C pillar trim Check sheetmetal clips 9 and replace if necessary Po...

Page 1693: ...the seat belt height adjuster release 3 must always be replaced 1 5 Fitting the clothes hook bracket Insert the clothes hook bracket 1 carefully into the aluminium bracket at the top Note The clothes...

Page 1694: ...emoving and installing A pillar trim Cabriolet Removing A pillar trim Installing A pillar trim Tightening torques top of page Removing A pillar trim 70 57 19 Removing and installing A pillar trim Cabr...

Page 1695: ...ble top peg housing 2 2 Unclipping the A pillar trim Pull the A pillar trim 3 inwards along the windscreen frame in the direction of arrow 3 Removing the A pillar trim Remove the A pillar trim 3 upwar...

Page 1696: ...A pillar trim Clip in the A pillar trim 3 along the roof frame in the direction of arrow 3 Installing convertible top peg housing In order to avoid rattling noises each of the convertible top peg hous...

Page 1697: ...g torques Location Illustration Thread Tightening torque Nm ftlb Fastening screw for convertible top peg housing to cowl panel frame 1 M6 10 7 5 996630 996631 996620 996621 996650 996651 einordnung Ti...

Page 1698: ...0 75 19 Removing and installing side panel lining Removing side panel lining Installing side panel lining top of page Removing side panel lining 70 75 19 Removing and installing side panel lining 1635...

Page 1699: ...panel lining Unscrew hexagon socket head bolt 5 remove cover trim 6 Pull out locking tabs of the side panel lining 1 from the clips in the rear side panel arrow Lift locking tabs of the side panel on...

Page 1700: ...anel lining 1 on the inside of the rear side section and the inside of the lower side member and press the locking tabs into the clips Push on the cover 6 and tighten using the hexagon socket head bol...

Page 1701: ...pillar seal along the side panel lining using a plastic spatula arrow Installing B pillar Installing trim of A B and C pillars 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Instal...

Page 1702: ...moving and installing side panel lining Cabriolet Removing side panel lining Installing side panel lining top of page Removing side panel lining 70 75 19 Removing and installing side panel lining Cabr...

Page 1703: ...e front 5 Unscrew fastening screw 6 from the side panel lining 1 Press out collar 7 with a plastic spatula 4 Removing side panel lining Loosen the fastening screws 9 from the loudspeakers Unscrew the...

Page 1704: ...Press clip 8 into the inside rear side section Clip must engage audibly Position fastening screw 12 into the sheetmetal bracket in the cut out for the loudspeaker and tighten Plug in electrical plug...

Page 1705: ...ce Fasten the side panel lining with the fastening screw 6 Press the locking tabs of the cover 4 into the clips 5 4 Fitting seal Lift up the pillar seal along the side panel lining using a plastic spa...

Page 1706: ...ront Installing front roof lining Removing rear roof lining Installing rear roof lining Removing and installing side roof lining Tightening torques A Front roof lining B Rear roof lining C Side roof l...

Page 1707: ...ic motor until the convertible top compartment lid has reached the rear end position Move convertible top forward by means of the electric motor until the convertible top compartment lid moves forward...

Page 1708: ...n this position 1 Removing convertible top lock Unscrew fastening screws 1 and remove convertible top lock 2 Disconnect electrical plug connection 3 2 Unscrewing fastening screws Unscrew the fastening...

Page 1709: ...Removing and installing side roof lining 7 Opening the Velcro fastening Open the velcro fastening 13 of the roof lining on the corner bow 8 Removing bracing straps Unscrew fastening screw 14 from the...

Page 1710: ...into the rear groove 2 Pulling in bracing strap Pull bracing strap X into the plastic connection of the roof lining V 3 Fitting velcro fastening Press the velcro fastening 13 of the roof lining onto...

Page 1711: ...connection 10 on the main bow in direction of arrow Tighten the connection on the left and right with the fastening screws 9 No Procedure Instructions 6 Installing roof lining connection on front roof...

Page 1712: ...and right with the fastening screws 4 10 Installing convertible top lock Plug in electrical plug connection 3 Position convertible top lock 2 on roof frame 1 Coat the fastening screws 1 with high str...

Page 1713: ...ap Z on the left and right and from the rear roof lining 21 4 Removing tension hook of side metal struts Bend brace 20 and remove from tension bow at the front in direction of arrow Remove brace from...

Page 1714: ...uently knock open the metal clips with a plastic hammer Make sure that the metal clips engage in the frame cutouts 2 Installing roof liner connection to tension bow Press the roof lining connection 23...

Page 1715: ...se the velcro fastening on the side roof lining on the left and right See Installing side roof lining top of page Removing and installing side roof lining Removing side roof lining 1 Opening the Velcr...

Page 1716: ...ded in scope of replacement parts 2 Closing the Velcro fastening Close the velcro fastening connection 11a between the roof lining 11 at the side and the corner bow 11b in direction of arrow top of pa...

Page 1717: ...72 01 19 Removing and installing front seat Removing front seat Installing front seat top of page Removing front seat 72 01 19 Removing and installing front seat 1654...

Page 1718: ...osition and undo the front M10 x 28 Torx screws 3 from the right and left seat rails using an E12 socket wrench insert 3 Undoing seat screws at rear Move seat to its front limit position and undo the...

Page 1719: ...screw the rear M10 x 28 Torx screws 3 into the seat baseframe on the left and right using the E12 socket wrench insert and tighten with tightening torque 65 Nm 48 ftlb 3 Fitting seat screws at front...

Page 1720: ...Push seat rail cover 2 into front end of the left and right seat rails Tighten the seat rail cover with the sheetmetal screws 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Instal...

Page 1721: ...19 Removing and installing cushion carrier Removing front cushion carrier Installing front cushion carrier top of page Removing front cushion carrier 72 21 19 Removing and installing cushion carrier...

Page 1722: ...itch for the seat adjustment 5 Pull the switch upwards and pull to the front arrow Subsequently remove through the opening of the cushion carrier direction of arrow 3 Disconnecting wiring harness Disc...

Page 1723: ...nstructions 1 Installing wiring harness Plug in electrical plug connection of the seat heating 7 or insert the wiring harness into the cushion carrier in the plastic clip in direction of arrow Clip in...

Page 1724: ...pening and position Secure the switch with the fastening screws 4 4 Installing control module and cover Position control module 3 and tighten with the fastening screws 2 Push on cover 1 in direction o...

Page 1725: ...port Removing electrical line for the lumbar Removing lumbar support Installling lumbar adjustment device for the lumbar support Installing motor for the lumbar support Installing electrical line for...

Page 1726: ...r adjustment device without control module memory Pull electrical plug connection E and F apart Pull white air hose A off the lumbar with pressure switch D air hose B red and C blue 2 Lumbar adjustmen...

Page 1727: ...ustment using a pair of side cutters 5b Electrical plug connection 6 for lumbar without control module for seat memory Pull plug connection 6 apart below the seat 6 Electrical line 7 Observe lead rout...

Page 1728: ...emory Position lumbar adjustment device and secure on backrest frame with the fastening screw arrow Tightening torque 6 Nm 4 5 ftlb 2 Lumbar adjustment device without control module memory Connect air...

Page 1729: ...rol module for seat memory Join plug connection 6 below the seat 6 Electrical line 7 Lay line behind motor for along the lumbar support Observe routing under the lumbar support airbag and along the se...

Page 1730: ...Take cover off backrest check connections for air hose lumbar support and valve block Check pressure switch and hose routing and replace if necessary End 4 Check fuse in the fuse box for the lumbar S...

Page 1731: ...72 86 19 Removing and installing switch for seat adjustment Removing switch for seat adjustment Installing switch for seat adjustment 72 86 19 Removing and installing switch for seat adjustment 1668...

Page 1732: ...odule 4 in connection with seat memory Undo fastening screws 3 Detach control module 4 and fold it to the front Pull out plugs arrow of control module together Unclip plugs beginning on the right natu...

Page 1733: ...h for seat adjustment No Procedure Instructions 1 Line C of seat adjustment switch B Push the plugs of line C one after the other through the opening below the seat cushion A 2 Line route 9 In connect...

Page 1734: ...tarting on the right natural blue black and plug on to the control module arrow Insert control device 4 into the mount and screw in the fastening screws 3 Tightening torque 6 Nm 4 ftlb 5 Installing sw...

Page 1735: ...ric motor for seat adjustment Installing electric motor for seat adjustment Tools Test plan for the seat adjustment A Electric motor for seat adjustment top of page Removing electric motor for seat ad...

Page 1736: ...ory Unscrew fastening screws 5 and fold control module 6 to front arrow 5b Plug connection 7 without seat memory control module Press plugs together in direction of arrow and pull apart Press out the...

Page 1737: ...y twisting slightly 2 Electric motor 3 Push motor 3 onto the shaft and ensure that the square fits into the mount on the motor by twisting slightly 3 Fastening screws 2 Position electric motor 3 with...

Page 1738: ...at functions vary the test plan principally complies with the seat version with seat memory adjustment Work aids Use wiring diagram and multimeter Tools Work instruction Correct result Incorrect resul...

Page 1739: ...Remove faulty part End 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Test plan for the seat adjustment 1676...

Page 1740: ...adjustment Installing electric motor for front seat height adjustment Tools Test plan for the front seat height adjustment A Electric motor for the seat height adjustment top of page Removing electri...

Page 1741: ...crews 5 Detach control module 4 and fold it to the front Pull out plugs of control module arrow 4b Plug connection 6 without seat memory control module Press plugs 6 together and pull apart arrow Pres...

Page 1742: ...unt on the motor by twisting slightly 3 Fastening screws 1 Position electric motor 2 with both fastening screws 1 and tighten screws Tightening torque 7 Nm 5 0 ftlb 4 Electric line Observe line routin...

Page 1743: ...t 1 Actuate switch on seat for seat height adjustment observe end position Switch in control module is audible Step 3 Step 2 2 Check fuse in the fuse box for the seat height adjustment Step 3 Replace...

Page 1744: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Test plan for the front seat height adjustment 1681...

Page 1745: ...ling electric motor for the backrest adjustment Installing electric motor for backrest adjustment Routing of wiring harness for the backrest adjustment Tools Test plan for the backrest adjustment devi...

Page 1746: ...ing washer 1 Lever the clamping washer 1 off the input shaft 2 using a screwdriver Cover bearing surface for the screwdriver with a strip of wood or plastic with a square cross section 2 Undoing faste...

Page 1747: ...d 5 Backrest motor 4 Remove backrest motor downward direction of arrow 6 Electrical plug connection 5 Push both locking tabs of the plug connection outwards using a screwdriver and pull the plug 5 dow...

Page 1748: ...mping washer Counter input shaft 2 on the right side and push clamping washer on to the left side of the input shaft 2 using a 12 mm socket for example Installing covering for backrest Installing fron...

Page 1749: ...and 31 on the memory SG see wiring diagram using a multimeter 11V when switching from front back the voltage changes from to Step 4 If a function is not audible under step 1 replace the control module...

Page 1750: ...t adjustment Installing electric motor for rear seat height adjustment Tools Test plan for the rear seat height adjustment A Electric motor for the seat height adjustment top of page Removing electric...

Page 1751: ...ng screws 4 and fold control module 5 to the front Pull plug arrow 7 off the control module 4b Plug connection 6 without seat memory control module Press plugs 6 together in the direction of arrow and...

Page 1752: ...tly 2 Electric motor 2 Push motor 2 onto the shaft and ensure that the square fits into the mount on the motor by twisting slightly 3 Fastening screws 1 Position electric motor 2 with both fastening s...

Page 1753: ...with seat memory adjustment Work aids Use wiring diagram and multimeter Tools Work instruction Correct result Incorrect result 1 Actuate switch on seat for seat height adjustment observe end position...

Page 1754: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung Test plan for the rear seat height adjustment 1691...

Page 1755: ...cover for front seat cushion Removing cover for the front seat Installing cover for the seat cushion Tools and materials top of page Removing cover for the front seat 74 13 55 Replacing cover for fron...

Page 1756: ...on clips 2 Pull off the push on bead 3 surrounding the seat cover of the cushion carrier 2 Destroying plastic clips Destroy plastic clips 4 with a screwdriver Remove the seat cushion with the cushion...

Page 1757: ...part D Using the cushion clip pliers and the cushion clips E connect the integrated metal strut of the foam part B to the metal strut for the seat cover A covering strips Tools and materials 2 Mountin...

Page 1758: ...f creases form only short partial warming with the hot air gun is permissible Always observe the hot air temperature of approx 50 degrees Celsius 122 Fahrenheit No Procedure Instructions Remedying cre...

Page 1759: ...and installing centre backrest strip Removing the backrest centre strip Installing the backrest centre strip top of page Removing the backrest centre strip 74 19 19 Removing and installing centre bac...

Page 1760: ...ps 3 along the seat frame Pull backrest centre strip 1 downwards and out of the backrest shell 4 2 Unclipping the backrest centre strip Insert your hand into the top of the backrest covering and lift...

Page 1761: ...5 2 Attaching the backrest centre strip at the bottom inserting electrical plug connection Attach backrest centre strip 1 to the bottom of the backrest shell 4 Plug in backrest seat heating Clip elect...

Page 1762: ...t centre strip Removing covering for backrest centre strip Installing covering for backrest centre strip Tools and materials top of page Removing covering for backrest centre strip 74 19 55 Replacing...

Page 1763: ...ic frame 4 Detach the covering for the backrest centre strip 1 from all sides of the plastic frame 4 2 Cutting through the cushion clips Cut through the cushion clips 3 using side cutters Detach the b...

Page 1764: ...he cushion clip pliers A and the cushion clips 3 2 Engaging the backrest centre strip Attach the covering for the backrest centre strip 1 to all sides of the plastic frame 4 At the connecting webs of...

Page 1765: ...Explanation 1 Cushion clip pliers and cushion clips Nr 130 Gr 2 4 Workshop Equipment Manual 2 Cushion clips Spare part Gr 8 Parts Catalogue 3 Felt strips Spare part Gr 8 Parts Catalogue Seat 996420 99...

Page 1766: ...and installing control module for seat heating Seat heating line route Central plug Removing and installing pin housing for seat heating and belt buckle Tools Test plan for the seat heating top of pa...

Page 1767: ...t D with a thin screwdriver for example and remove the holder together with the rivet and the control module b Pull control module off the plug C 3 Installing control module for seat heating a Push co...

Page 1768: ...moving front seat a Pull slide B in direction of arrow 1 b Lever out fuse arrow 2 with a small screwdriver and remove completely c Pull out coding pin A with pliers Press pin out of flat connector usi...

Page 1769: ...nnector top of page Tools Item Designation Special tool Explanation 1 Press out tool for the crimp sockets No 155 Gr 2 4 Workshop Equipment Manual 1 Multimeter Gr 2 5 Workshop Equipment Manual top of...

Page 1770: ...Check resistance test on backrest and seat area heating elements via the respective connecting plug approx 1 and replace defect heating element End 4 Seat heating control module replace End 5 Check fu...

Page 1771: ...d insert 3 Insert two small screwdrivers into the openings and pull off the button A towards the front 4 Unclip the collar from the dashboard insert The hazard warning light switch B is held in the da...

Page 1772: ...ment cluster must be corrected with the Porsche System Tester 2 PST2 after the installation of a new instrument cluster in 911 Turbo vehicles If this correction is not carried out conflicting values f...

Page 1773: ...synchronised or the message K number updated appears in the Tester display If the K number is not updated a connection to the PCM is set up automatically The message Connecting to PCM appears 9 Then...

Page 1774: ...hen in driving mode PROCEDURE for changing the K number on PCM control module as of PST2 Software 13 0 1 Connect the PST2 to the diagnostic socket switch on the PST2 and the ignition 2 When the PST2 i...

Page 1775: ...talling display and operator control unit PCM Note After installation of a new display and operator control unit the system must be activated with the Porsche System Tester 2 1 Engage the electrical p...

Page 1776: ...y a device code Furthermore a code also protects the navigation unit against unauthorised users Note Both codes must be input when the system is commissioned Input the device code for the display and...

Page 1777: ...perator control unit PCM 2 The PCM has an optical waveguide LWL For information on the optical waveguide LWL 97 9768 Optical waveguide LWL Switch ignition off and remove ignition key 1 Unclip switch c...

Page 1778: ...e electrical plug connections in the order C B D top of page Installing display and operator control unit PCM 2 Note If a new PCM is being installed the navigation module must be removed from the old...

Page 1779: ...quence D B A and the antenna plugs A E and F until they are felt to engage 7 Check that the locking tabs on the PCM are out arrow opening the lock with a hexagon socket wrench if necessary Note Before...

Page 1780: ...aranteed Connect a battery charging device to the vehicle battery Symbol for the TAB key The Porsche System Tester instructions take precedence and in the event of a discrepancy these are the instruct...

Page 1781: ...tep 13 In the PCM2 MMI menu 13 Select Coding and press Note The following can be coded with software version 20 0 or higher 14 Select K number standard and code with the F8 key K number standard Turbo...

Page 1782: ...t are detected are displayed in the MOST actual installed components list Compare the installed components detected from the MOST actual installed components list with the MOST required installed comp...

Page 1783: ...essary Note Switch on the PCM2 If the PCM2 cannot be switched on or the PCM2 switches on but no music can be heard switch off the ignition remove the ignition key close the doors and lock the vehicle...

Page 1784: ...perfect contacts If the problem persists contact radio manufacturer End Does radio have a CD player or a magnetic tape drive Yes Check signal lead No Go to Step 2 2 Does radio have a display If an au...

Page 1785: ...ur in all program sources Find out whether it is a question of an objective fault go to Step 2 or a subjective perception go to Step 4 of the system behaviour If the problem only occurs in FM or AM ra...

Page 1786: ...nce noises Step 3 3 Are the interference noises still present 1 Check the audio cables between the radio and the amplifier for free points short circuits and high resistance 2 Check all cable connecti...

Page 1787: ...rical connections to retrofitted accessories such as two way radios mobile telephones radar detectors etc Step 2 End 2 Can the interference noise be heard in all the loudspeakers Slowly pull the recei...

Page 1788: ...se still present Step 4 2 5 With the radio switched off exchange the cables between the radio and the amplifier 6 Switch the radio on Is the loudspeaker involved in the complaint now OK 7 Check the pl...

Page 1789: ...d repair the connections and if necessary install a condenser End End Interference noises due to engine The following points should be checked first Note Make sure that the battery connections are sea...

Page 1790: ...eception End 3 8 Check the wiring of the components for unfavourable positioning and loose or corroded connections 9 Lay the leads again or repair Noise still present As an experiment insert a functio...

Page 1791: ...components End Interference noises due to power supply Note Use this test routine for interference noises which originate from the vehicle electrics Work instruction Yes No 1 1 Temporarily disconnect...

Page 1792: ...in the retrofitted accessories and remedy End The noise occurs when the engine is running Step 4 The noise occurs with the ignition switched on and the engine at standstill Step 5 4 Briefly disconnect...

Page 1793: ...d the positive cable of the suspected component and cut the cable at the component side 19 Insert an interference filter between the connecting cables End End Interference noises due to all looudspeak...

Page 1794: ...ay remove the relay and connect the amplifier directly to the power supply Noise still present 7 Localise the battery connecting cable of the amplifier 8 Cut this cable 9 Install an interference filte...

Page 1795: ...components Complaint still present Step 4 End 4 Check the wiring between the trigger and the receiver Ground connection Plug connections Positioning of wiring harness Complaint still present Consult P...

Page 1796: ...pter 2 2 2 Clips for removing radio top of page Removing the car radio Note If the car radio is replaced by a new or a different car radio read out the data with the Porsche System Tester before remov...

Page 1797: ...io 4 Unlock the plug connections by pressing the plug locking elements a and pull the plugs off the radio arrow Note The number of plug connections will vary depending on the I No CD changer Bose ampl...

Page 1798: ...until the locks engage on the radio housing top of page Teaching the car radio Note If a new car radio is to be installed in a vehicle the PCM2 CDR23 code specified in IPAS must be used You can get t...

Page 1799: ...the coding read it out and note it down if necessary 8 Switch off ignition and replace CDR23 Removing the car radio 9 Switch on ignition After replacing the CDR23 go back to the CDR23 menu using the k...

Page 1800: ...the items in the actual list differ from those in the required list update the MOST required installed components list to the status of the MOST actual installed components list by coding 24 Exit the...

Page 1801: ...d installing rear loudspeakers Bose sound package Removing rear loudspeakers Installing rear loudspeakers top of page Removing rear loudspeakers 91 42 19 Removing and installing rear loudspeakers Bose...

Page 1802: ...ew Unscrew the fastening screw 2 at the left and right 3 Pulling out the sound package Pull the sound package 3 in the direction of the arrow out of the bracket 4 and fold over 4 Disconnecting the plu...

Page 1803: ...ound package 3 into the bracket 4 as far as the stop 3 Fastening the sound package Screw in the fastening screws 2 at the left and right Tightening torque 7 2 Nm 5 5 ftlb 4 Attaching the cover trim Po...

Page 1804: ...ng the loudspeaker amplifier Installing the loudspeaker amplifier top of page Removing the loudspeaker amplifier Before removing the amplifier take out the ignition key and switch off the audio system...

Page 1805: ...irection of travel to the right 2 Press connectors arrow together and pull apart Remove additional amplifier 3 Unscrew both fastening screws from the retaining bracket Bose amplifier 4 Unplug both ele...

Page 1806: ...l the amplifier from the fastening clips top of page Installing the loudspeaker amplifier 1 Insert the amplifier in the retaining clip and secure with the two fastening screws 2 Insert both connectors...

Page 1807: ...fier and both fastening screws to the body 5 Plug in the connector of the additional amplifier and attach the additional amplifier on the retaining bracket and secure using the clip 1 996420 996421 99...

Page 1808: ...nt seat Before removing the control module remove the ignition key Removing front seat 720119 Removing and installing front seat top of page Removing control module for parking assistant 1 Unscrew bot...

Page 1809: ...control module until they engage 2 Fit the control module onto the cover with both fastening screws 3 Position the cover and screw tight with the fastening screws arrow 996420 996421 996450 996451 99...

Page 1810: ...003 Removing antenna amplifier Installing antenna amplifier Note The antenna amplifier is installed in connection with the PCM2 The antenna amplifiers are located on the A pillars top of page 91 84 19...

Page 1811: ...o fastening screws 6 top of page Installing antenna amplifier 1 Position the antenna amplifier on the A pillar and screw the fastening screws 6 tight 2 Connect the plug connections for the antenna con...

Page 1812: ...ng control module for antenna top of page Removing control module for antenna Remove the right cover under the instrument panel 7 702219 Removing and installing cover under instrument panel Remove the...

Page 1813: ...e in the direction of the arrow A and carefully pull it over the passenger compartment carpet B pay attention to the length of the lead 3 Disconnect the electrical plugs successively top of page Insta...

Page 1814: ...le in the holder A 3 Fasten the control module with the clip on the holder Install the right cover under the instrument panel 7 702219 Removing and installing cover under instrument panel 996420 99642...

Page 1815: ...alling front seat Switch off ignition remove key switch off PCM or radio top of page Removing control module for telephone 1 Unscrew the 4 fastening screws from the holder 2 Unscrew the 2 fastening sc...

Page 1816: ...and screw the fastening screws tight Tightening torque 10 Nm 7 5 ftlb 3 Lay the holder with the control module on the floorpan and fasten with the 4 fastening screws Install right front seat 7 720119...

Page 1817: ...installing rain sensor Removing rain sensor Installing rain sensor Open circuit in the rain sensor connection emergency interval operation top of page Removing rain sensor 92 12 19 Removing and instal...

Page 1818: ...indscreen and the adhesive pad or between the adhesive pad and the rain sensor When installing the adhesive pad a temperature of approx 20 C for the windscreen the rain sensor and the adhesive pad mus...

Page 1819: ...If the old rain sensor is installed begin with the instructions on Page 5 No Procedure Instructions 1 Removing cover of infra red interior sensor Remove both covers and unscrew both screws 1 2 Line ro...

Page 1820: ...emoving mirror Fold mirror 4 downwards and push down from the bracket 5 Unclipping rain sensor holder Carefully unclip holder 5 of rain sensor at the top bottom left and right 6 Undoing rain sensor fr...

Page 1821: ...cedure Instructions 1 Sticking on rain sensor Push the rain sensor 6 onto the windscreen 2 Clip in holder Push and press holder 5 onto the rain sensor until it engages 3 Push on rearview mirror Push r...

Page 1822: ...tions 1 Connecting the plug connection Press the plug connection 3 together 2 Line routing Engage holder 2 for the line and push in line behind the headliner 3 Mounting cover of infra red interior sen...

Page 1823: ...to six sensitivity stages wiping interval stages as a remedial measure 1 Ignition on and activate rain sensor 2 If the windscreen wiper switches on intermittently the rain sensor or the wiring must b...

Page 1824: ...odule for rain sensor Installing control module for rain sensor Safety function in the event of failure engine blockage Note The control module for the rain sensor is located under the left cowl panel...

Page 1825: ...iper system and when the wiper reaches a vertical position on the windscreen turn off the ignition 1 Removal of cover for rain sensor control module Unscrew fastening screws for cover Switch on igniti...

Page 1826: ...on top of page Installing control module for rain sensor WARNING When working in the area of the wiper link the ignition key must be removed No Procedure Instructions 1 Connect control module with the...

Page 1827: ...event of failure engine blockage Note Two types of motor blockage can be distinguished in the rain sensor control module 1 The front windscreen wiper does not leave the parking position when activate...

Page 1828: ...nection with the the parking assistant control module a new bracket from model year 2002 a new tilt sensor a bracket for the tilt sensor and a wiring harness will be required for the conversion Discon...

Page 1829: ...for alarm system 9 Disconnect the plug of the alarm control module open the plug A and pull out the pin strip B 10 Remove pins 38 and 11 with the press out tool 90207 insulate the lead and tie it to...

Page 1830: ...and insert both plugs into the control module Pay attention to the new installation position 18 Insert the tilt sensor 3 into the cover 1 and screw the cover tight to the floorpan using the fastening...

Page 1831: ...arm system Removing control unit for alarm system Installing control unit for alarm system Teaching control unit for the alarm system top of page Removing control unit for alarm system 96 87 19 Removi...

Page 1832: ...AS are required In order to prevent possible complications when teaching the transponder and radio codes use the spare key as well The control unit for the alarm system can only be taught for one vehi...

Page 1833: ...unit out of the bracket and turn it around 2 Disconnecting the connectors Press connectors 2 together and pull apart 3 Disconnecting the connectors Press the locking arrow fold back the lever and pul...

Page 1834: ...an no longer be changed The described teaching process was implemented with Tester version 12 0 Later software versions may feature expanded contents The instructions or prompts of the Porsche System...

Page 1835: ...menu Alarm system select Coding in the menu Country coding the respective country in which the vehicle is used and the vehicle model sliding roof Cabrio can be coded with F8 13 In the menu Version cod...

Page 1836: ...Removing and installing current distributor Removing current distributor Installing the current distributor top of page Removing current distributor 97 89 19 Removing and installing current distribut...

Page 1837: ...ning nuts 3 2 Cover in passenger s footwell Unscrew both plastic screws 4 and remove the cover 5 downwards 3 Lowering the current distributor Disconnect the tie wrap 7 from the water drainage 6 and pu...

Page 1838: ...sitive lead B B Disconnect tie wrap 9 top of page Installing the current distributor Note The following spare parts must be installed again Hexagon nut M 6 7 pieces Hexagon nut M 8 2 pieces Service la...

Page 1839: ...osing and sealing the current distributor Close the cover until both locking elements arrow engage Affix the service label 8 red 3 Installing the current distributor Check the flange seal between the...

Page 1840: ...Nm 11 ftlb Press cover cap 1 on 5 Cover in passenger s footwell Position the cover 5 from below and screw tight with the two fastening screws 4 Connecting the battery 9 Work instructions after discon...

Page 1841: ...sible element from the current distributor Removing current distributor 1 Remove cover for current distributor and remove the service label 2 Carefully lever off the cover A e g with a screwdriver arr...

Page 1842: ...ment fusible element 1 Insert new fusible element 1 using new washers 2 and new hexagon nuts 3 M 5 Tightening torque 4 Nm 3 ftlb 2 Position and engage the blue after sales service cover A 3 Close the...

Page 1843: ...n of course the generally customary basic safety rules for the repair of motor vehicles are unrestrictedly applicable top of page Structure Overview of repair groups Table of Contents Technical data g...

Page 1844: ...Page number F Internal Porsche number G Work operation consisting of After sales service number and Title H Imprint year of printing I Title of legend for structure J Structure of legend N Structure o...

Page 1845: ...E Page number F Internal Porsche number G Work operation consisting of After sales service number and Title H Imprint year of printing I Title of exploded drawing J No of exploded drawing in order of...

Page 1846: ...r explanation of procedure top of page Structure of sequence description A Repair Group number B Repair Group number C Repair group text D Vehicle type E Page number einordnung Structure of sequence d...

Page 1847: ...nting I Title of structure sequence description J Sequence number in order of sequence K Sequence number in order of sequence L Procedure in the sequence M Description or explanation of procedure 9964...

Page 1848: ...nic Sheet 11A Seat Sheet 11B Transmission cooling GT2 Sheet 12 DME vehicle area Sheet 12A DME engine area Sheet 13 Radio for standard GT2 Sheet 13A Radio sound package Sheet 14 Parking assistant Sheet...

Page 1849: ...mber In the case of wires that branch off onto another sheet the coordinates and in some cases the terminal designations are specified 996420 996421 996450 996451 996620 996621 996650 996651 einordnun...

Page 1850: ...indows Sheet 8 Central locking alarm system LHD Sheet 8A Central locking alarm system RHD Sheet 9 Airbag POSIP LHD Sheet 9A Airbag POSIP RHD Sheet 10 ABS GT2 Sheet 10A PSM Sheet 11 Tiptronic Sheet 11A...

Page 1851: ...rriers and fuses The individual wiring diagrams are subdivided into coordinate fields The ground points are identified with GP and their locations are shown in a vehicle diagram The plug connections a...

Page 1852: ...Power windows Sheet 8 Central locking alarm system LHD Sheet 8A Central locking alarm system RHD Sheet 9 Airbag POSIP LHD Sheet 9A Airbag POSIP RHD Sheet 10 ABS GT2 Sheet 10A PSM Sheet 11 Tiptronic S...

Page 1853: ...am consists of individual circuit diagrams and overview sheets for ground points components plug connections connection points relay carriers and fuses The individual circuit diagrams are subdivided i...

Page 1854: ...ted convertible top Sheet 7 Power windows Sheet 7A Power windows Cabrio Sheet 8 Central locking alarm system LHD Sheet 8A Central locking alarm system RHD Sheet 9 Airbag POSIP LHD Sheet 9A Airbag POSI...

Page 1855: ...ircuit diagram consists of individual circuit diagrams and overview sheets for ground points components plug connections connection points relay carriers and fuses The individual circuit diagrams are...

Page 1856: ...ted convertible top Sheet 7 Power windows Sheet 7A Power windows Cabrio Sheet 8 Central locking alarm system LHD Sheet 8A Central locking alarm system RHD Sheet 9 Airbag POSIP LHD Sheet 9A Airbag POSI...

Page 1857: ...overview The circuit diagram consists of individual circuit diagrams and overview sheets for ground points components plug connections connection points relay carriers and fuses The individual circuit...

Page 1858: ...er condition Repair works on Porsche vehicles must be carried out with the tools and workshop equipment recommended and approved by the Dr Ing h c F Porsche AG All body repair work must be carried out...

Page 1859: ...es the work procedure easier Due to the continuous development and improvement of our vehicles there may be discrepancies between the actual technical status of the vehicles and the work descriptions...

Page 1860: ...t locating pegs on convertible top to ensure that they are secure and functioning properly 4 Check the convertible top peg housing on cowl panel frame to ensure that it is secure and functioning prope...

Page 1861: ...996420 996421 996450 996451 996430 996431 996620 996621 996650 996651 996630 996631 einordnung Checking the hardtop 1798...

Page 1862: ...protection 2 Visual inspection for scratches and chips caused by flying stones 3 Visual inspection for damage to surrounding section or rubber profile of glazing 996420 996421 996450 996451 996430 996...

Page 1863: ...lower part of the lock of the safety hook after the lid lock is opened 2 Check whether the return spring on the lower part of the lock pulls back the safety hook as far as the stop top of page Functio...

Page 1864: ...en removing the transport protection 2 Visual inspection for scratches and scoring 3 Visual inspection for soiling of interior equipment 996420 996421 996450 996451 996430 996431 996620 996621 996650...

Page 1865: ...ilm white X Roof Hardtop PP film white X X X X Targa roof frame excluding protection Left and right wing PP film white X X X X Side panel left and right PP film white X X X X Side member Aerokit on th...

Page 1866: ...l IKS adhesive tape blue X Inner side member Polypropylene film X Door trim panel at bottom loudspeaker TESA transparent film red X Footwell Cardboard insert X Steering wheel Film covering X Parking b...

Page 1867: ...re must be replaced immediately Spoilers and undersides must therefore be regularly checked for damage Please inform the customers concerned about this top of page Installing front air guides 1 Mount...

Page 1868: ...ining clip 2 to the air guide 1 To this purpose push the three expansion rivets 3 included in the scope of delivery into the bores drilled in the bracket and the air guide two from above and one from...

Page 1869: ...ing screws included with the vehicle must be fitted Note Lift the vehicle on a lifting platform to fit the front spoiler 1 Insert the front spoiler 1 into the groove on the front end Ensure that all l...

Page 1870: ...int seat belt through the openings in the bucket seat Pull six point seat belt through the upper openings in the backrest from behind arrow A and through the openings in the seat frame from the side a...

Page 1871: ...he direction of the arrow inset around the transverse strut on the roll cage into the adjustible slider The projection dimension X of the belt strap must be at least 100 mm b Roll up the projecting be...

Page 1872: ...t Check the Vehicle Ident No on the data bank self adhesive label in front inner cover Stick the lower data bank self adhesive label on the front inner cover in the on board literature Guarantee and M...

Page 1873: ...Check for surface damages dents bulges or secure fitting of accessories such as front door mirrors and rear spoiler door front and rear cover top of page Checking paint finish Check for scoring scratc...

Page 1874: ...oupe Cabrio Coupe Cabrio Japan Europe Germany Warning triangle X X X X X X Emergency kit X X X X X X Tool case X X X X Tools Tools Socket for security wheel bolts X X X X X Car jack X X X X Vehicle ke...

Page 1875: ...mposite Brakes X X X Allen socket wrench for emergency unlocking under the trim operating buttons for sliding roof X X Allen socket wrench for emergency unlocking behind the rear emergency seat trim X...

Page 1876: ...data Manual transmission G 96 50 Transmission ratios Z1 Z2 Z2 Z1 1 gear 11 42 3 82 2 gear 21 43 2 05 3 gear 27 38 1 41 4 gear 34 38 1 12 5 gear 37 34 0 92 6 gear 40 30 0 75 Reverse gear 14 40 2 86 Fi...

Page 1877: ...33 ftlb Air flanges on transmission M6 10 7 5 ftlb Bracket for clutch control shaft on transmission M6 x 16 10 7 5 ftlb Guide tube for release bearing on transmission housing M6x14 10 7 5 ftlb Transm...

Page 1878: ...ly shaped front end with enlarged air inlet openings for the chilled air supply of the radiators and of the front wheel brakes Moreover the 911 GT2 is equipped with a large non retractable rear spoile...

Page 1879: ...adjustment range of the axle geometry for racing purposes and the related specific requirements e g camber Reinforcement of relevant components e g wheel carrier and front wheel bearing for possible u...

Page 1880: ...rbo 996 top of page Adjustment operations on the spring struts The front and rear axle spring strut has a thread and a height adjusting nut 2 for height adjustment The height adjusting nut 2 is secure...

Page 1881: ...values on the front and rear axle differ in a number of respects from those of the 911 Turbo 996 Adjusting values in Repair Group 44 The suspension alignment of the 911 GT2 is described after the sus...

Page 1882: ...on the front axle and 4 piston on the rear axle are painted yellow The GT2 is equipped with 3 channel ABS ABS 5 3 without PSM and without TC Traction Control Because of the larger brake disc diameter...

Page 1883: ...onto lifting platforms and wheel alignment platforms top of page Wheel alignment platform It is only possible to drive onto wheel alignment platforms if additional access ramps for example 959 access...

Page 1884: ...urrent adjustment Position 4 arrow The new adjustment Position 4 can also be used arrow for vehicles with a Stabi center position position 3 The rear stabilizer with 20 7 x 2 8 mm diameter is adjusted...

Page 1885: ...es Front and rear racing camber values should only be adjusted for use on racing tracks Only the values listed in Repair Group 44 are permitted for use on public roads 996840 996841 einordnung Racing...

Page 1886: ...n for measurement Make of tires Size model at front Rear front left front right rear left rear right Tire pressure of cold tires bar Tire wheel any damage Tires tread depth mm Incoming measurement Nom...

Page 1887: ...cle and M003 Club Sport version 1 Prepare copies of the corresponding alignment card shown 2 Before measurement enter the general data vehicle model and the missing nominal values into the copied alig...

Page 1888: ...ccess ramps for example 959 access aids are required to drive the vehicle onto the measuring platform Otherwise the front spoiler would bottom on the platform A measuring platform without a sloped pos...

Page 1889: ...ength depending on the wheel alignment tester This is the only means of enabling data transfer from the right side to the left The wheel alignment testers recommended by Porsche which have a spoiler m...

Page 1890: ...the other wheels A one sided increase in the installed spring preload raising vehicle increases the wheel load A one sided decrease in the installed spring preload lowering vehicle decreases the wheel...

Page 1891: ...differences lie within a permissible range provided that the coil springs have the same installation position installed spring preload on each axle Tolerance 1 mm Wheel load differences can be kept as...

Page 1892: ...with special tool 9647 in conjunction with a torque wrench Tightening torque No 1 50 Nm 37 ftlb If the vehicle is measured front and rear check and adjust the rear axle first Nominal values in Repair...

Page 1893: ...es one 1 mm thick adjustment plate By using thicker adjusting shims the 2 part control arms permit a correspondingly increased camber value to be obtained for circuit use In relation to this observe a...

Page 1894: ...ting diagonal control arm on control arm GT2 Note In the case of the road version of the GT2 M002 and M003 the diagonal control arm must be fitted at the centre bore No 1 of the control arm Control ar...

Page 1895: ...arm right C Direction of travel 1 Centre bore for GT2 road model 2 Rear bore only for Cup vehicle with racing circuit camber values 996840 996841 einordnung Instructions for fitting diagonal control...

Page 1896: ...e cap is automatically punctured 3 Remove the valve cap from the tyre valve and unscrew the valve insert with the accompanying valve insert driver and set it aside on a clean surface 4 Remove the seal...

Page 1897: ...to the correct value again if necessary see sticker in the filler flap and continue the journey as far as the next workshop 8 Affix the accompanying sticker in the driver s field of view 9 Continue t...

Page 1898: ...mic brake discs production launch with cast iron brake discs Hydraulic dual circuit brake system with front axle rear axle brake circuit distribution Vacuum brake booster internally ventilated and per...

Page 1899: ...nsions Wear limit Pad thickness front approx 12 0 mm 2 mm rear approx 12 0 mm 2 mm Brake disc thickness new front 34 mm rear 28 mm Brake discs minimum thickness front PCCB 33 5 mm steel 32 0 mm rear P...

Page 1900: ...adustment possibility is only useful for racing It can be used to ensure that enough clearance is available for the stabilizer mount even for deviating vehicle heights only for racing and also that t...

Page 1901: ...t at the piston rod with a countering tool Sonderwerkzeug 9630 or a 7 mm Allen key when loosening the nut Use new fastening nut Grease thread of the piston rod with Optimoly HT copper paste Tighten to...

Page 1902: ...ve bellows 1 11 Spring strut mount 1 The spring strut mounts for the right and left sides are identical parts In the case of used mounts the bearing shell can be regreased with Autol Top 2000 Manufact...

Page 1903: ...to the new vibration damper To do this a hook wrench insert Sonderwerkzeug 9647 is required Tightening torque of the lock nuts 1 3 50 Nm 37 ftlb The stabilizer mating bearing mounting saddle 4 need no...

Page 1904: ...opper grease only at the front axle 3 Push the assembly of the spring strut mount 2 consisting of Parts No 8 No 9 No 10 No 11 onto the piston rod Note The mounts for the right and left sides are ident...

Page 1905: ...a socket wrench insert wrench size 22 mm open on one side to tighten the fastening nut on the spring strut mount 5 When tightening the fastening nut hold at the piston rod using a countering tool Son...

Page 1906: ...ertically adjusted and it is provided with a lock nut 3 This adjustment possibility is only useful for racing It can be used to ensure that enough clearance is available for the stabilizer mount even...

Page 1907: ...before loosening the fastening nut This depends on the pre tension of the coil spring Support at the piston rod with a countering tool Sonderwerkzeug 9630 or an open ended wrench 7mm when loosening t...

Page 1908: ...6 Coil spring 1 Available as spare part only in sets Mount in correct position tighter winding downwards The coil spring is fitted as standard with a protective sheath at the top and bottom as of mode...

Page 1909: ...ding on the spring preload with the spring clamp until the piston rod is relieved 2 To undo the connection piston rod to spring strut mount counter at the piston rod with countering tool Sonderwerkzeu...

Page 1910: ...nd rear axle The special tool is used together with a torque wrench to tighten the lock nuts slotted nuts on the spring struts Assembly 1 Slide the additional spring 9 washer 8 and stop plate 7 stop p...

Page 1911: ...n on the spring strut mount Note Replace nut for fastening the piston rod on the spring strut mount 5 Screw new fastening nut onto the piston rod until approx 1 to 2 threads are visible above the fast...

Page 1912: ...8 When tightening the fastening nut hold at the piston rod using a countering tool Sonderwerkzeug 9630 or a 7 mm open ended wrench 996840 996841 einordnung Assembly 1849...

Page 1913: ...e fluid This brake fluid is available under the following part numbers container volume 1 litre 000 043 203 66 container volume 30 litres 000 043 203 67 top of page Filling bleeding DANGER Please note...

Page 1914: ...the system was open previously e g for component replacement the minimum filling or bleeding time must be 30 seconds 4 Switch off and disconnect the bleeding device Correct the brake fluid level if n...

Page 1915: ...tion 1 Snap ring 1 Remove using pointed nose pliers simultaneously push down pressure plate using a press Ensure correct seating 2 Thrust plate 1 Engage lug twist lock in the opening of a diaphragm sp...

Page 1916: ...ved under a shop press For this purpose lay the release bearing down on the bottom and press down on the pressure plate from above with a pressure piece e g hardwood block until the snap ring can move...

Page 1917: ...the parts are fitted in the correct order and the spring washer is seated properly 2 Insert release bearing in diaphragm spring plate Engage lug on release bearing twist lock in the opening between t...

Page 1918: ...Tightening torques top of page Tools Item Designation of the special tool Explanation A Toothed segment P201b B Centring mandrel 9102 top of page Removing clutch 1 Remove transmission 34 35 27 Removi...

Page 1919: ...te To do so position the special tool toothed segment P201b A on the stud and tighten the pan head screws in several stages and in diametrically opposite sequence Tightening torque 23 Nm 17 ftlb 3 Rem...

Page 1920: ...n order to avoid deformation of the thrust plate housing tighten screws in several stages and in diametrically opposite sequence 2 Release bearing 1 Do not wash out the bearing replace loud bearings d...

Page 1921: ...Remove rear centre and left underbody trim 2 Unscrew oil filler plug 1 3 Unscrew oil drain plug 2 and let oil drain off into a suitable container top of page Topping up transmission oil GT2 1 Clean t...

Page 1922: ...Tightening torques Location Thread Tightening torque Nm ftlb Oil filler plug M22 x 1 5 30 22 ftlb Oil drain plug M22 x 1 5 30 22 ftlb 996840 996841 einordnung Tightening torques 1859...

Page 1923: ...Tools Item Designation of the special tool Explanation A Gripper Commercially available Rep Gr Workshop Equipment Manual Chapter 2 4 No 50 B Removal mandral Special tool 9287 top of page Removing tran...

Page 1924: ...attausr stung Kapitel 2 4 Nr 50 or lever off with screwdriver 6 Screw a screw M6 into the clutch control shaft and pull out shaft 7 Unscrew the fastening nuts for engine transmission and separate the...

Page 1925: ...ect position in the transmission housing and mount transmission on the engine 3 Ensure that the closure cap A is properly seated and positioned 4 Fit release lever shaft with sealing rings 1 Hexagon h...

Page 1926: ...ning torque 45 Nm 33 ftlb 9 Fit air flanges Tightening torque 10 Nm 7 5 ftlb 10 Engage starter cable and push vacuum line onto coolant valve 11 Install engine transmission unit 100119 top of page Tigh...

Page 1927: ...l threaded piece VW 771 15 E Pressure piece Special tool pressure piece P 254 b F Pressure piece Special tool pressure piece 3062 G Pressure piece Special tool pressure pieces 9247 H Pressure pieces S...

Page 1928: ...b P Pressure piece Special tool pressure piece 9648 1 Q Pressure piece Special tool pressure piece 9648 top of page Overview No Designation Qty Removal Installation 1 Screw plug with sealing ring 1 Cl...

Page 1929: ...th special tool drift P 264 b Drive in with special tool pressure piece P 254 b and special tool pull in tool and extractor P 254 8 Circlip 1 Fit in correct position and make sure it is seated properl...

Page 1930: ...1 Remove closure cap To do this drill a 3 5 mm hole into the centre of the cap screw in a sheetmetal screw 4 8 x 25 with large washer and lever the cap out using two screwdrivers Assembly 1 Fit selec...

Page 1931: ...sition and make sure it is seated properly top of page Tightening torques Location Thread Tightening torque Nm ftlb Plug screw no 1 in overview M22 x 1 5 30 22 Bearing screw no 19 in overview 50 37 99...

Page 1932: ...ce Special tool Pressure piece P 254 a D Mandrel Special toolPull in tool and extractor P 254 E Threaded piece Special tool Threaded piece VW 771 15 F Internal puller 14 20 mm Commercially available H...

Page 1933: ...top of page Overview No Designation Qty 1 Screw plug 1 2 Snap ring 1 3 Outer bearing race 1 4 Snap ring 1 5 Snap ring 1 6 Outer bearing race 1 7 Snap ring 1 8 Ball sleeve 1 einordnung Tools 1870...

Page 1934: ...ear set 3 Remove gear housing Disassembling gearshift 1 Unscrew screw plug no 12 in overview and remove compression spring and locking pin no 13 and 14 in overview 2 Remove circlip no 15 in overview w...

Page 1935: ...7 in overview from groove in outer bearing race Removing ball sleeves 1 Knock out ball sleeve no 8 to 11 in overview outwards with internal puller 14 20 mm and special tool striker VW 771 Removing scr...

Page 1936: ...ace 2 Drive in outer bearing race no 3 or 6 in overview with special tool pressure piece P 254 b or special tool pressure piece P 254 a and special tool pull in tool and extractor P 254 from the outsi...

Page 1937: ...996840 996841 einordnung Tightening torques 1874...

Page 1938: ...ch Werkstattausr stung Kapitel 2 4 Nr 108 B Counter support Commercially available Handbuch Werkstattausr stung Kapitel 2 4 Nr 106 C Internal puller 30 40 mm Commercially available Handbuch Werkstatta...

Page 1939: ...head bolt 1 2 Bearing segment 1 3 Reverse idler gear 1 4 Needle roller bearing 2 5 Pin 1 6 Snap ring large 1 7 Outer bearing race 1 8 Snap ring small 1 9 Cylindrical roller bearing 1 10 Reversing lig...

Page 1940: ...sion housing 6 Remove oil cooler To do this undo screws B and lift oil cooler up and off 7 Unscrew fastening screws for front transmission case cover and remove transmission case cover Disassembling r...

Page 1941: ...ler bearing Ensure correct seating 5 Screw internal puller together with counter support and pull out cylindrical roller bearing by turning the nut on the counter support Disassembling outer bearing r...

Page 1942: ...Nm 7 5 ftlb 3 Fit connecting hose between oil cooler and transmission 4 Fit electric cable 5 Fill with transmission oil 34 01 55 Changing transmission oil GT2 6 Refitting transmission 34 35 27 Removin...

Page 1943: ...of page Tightening torques Location Thread Tightening torque Nm ftlb Hexagon head bolt no 1 in overview M 8 25 18 5 ftlb Transmission case cover fastening screws on transmission housing M8 23 17 ftlb...

Page 1944: ...l pump Tightening torques top of page Tools Item Special tool designation Remarks A Removal tool Shop made flat steel 5 x 230 top of page Removing transmission oil pump 1 Remove the transmission oil c...

Page 1945: ...e g with Liqui Moly 2 Drive the transmission oil pump carefully into the transmission housing with a rubber hammer 3 Screw in the fastening screws between the transmission oil pump and the transmissi...

Page 1946: ...ing torques CAUTION The described operation must not be performed on vehicles with an engine at operating temperature Risk of injury due to hot transmission oil or coolant top of page Tools Item Speci...

Page 1947: ...mission oil GT2 3 Unscrew two hexagon head bolts A and remove the transverse strut 4 Disconnect the plug B and remove the electrical cable from the working area 5 Disengage the coolant line for the he...

Page 1948: ...r under the vehicle to collect the coolant oil mixture from the transmission oil cooler WARNING Coolant and transmission oil may emerge during the repair operations described below With the engine at...

Page 1949: ...lb 5 Connect the coolant hose to the oil cooler and connect the spring band clamp 6 Remove special tool hose clamp VW3093 from the coolant hoses 7 Screw the transmission oil connecting line into place...

Page 1950: ...tening of cooler bracket to oil pump M 6 x 55 10 7 5 Fastening of oil cooler holder to transmission housing M 8 x 20 23 17 Fastening of transmission oil line to transmission oil cooler 34 25 Fastening...

Page 1951: ...on Remarks 1 Pressure piece Special tool Pressure piece 9256 2 Assembly sleeve Special tool Assembly sleeve 9255 3 Puller Special tool Puller 9629 top of page Removing sealing ring for drive shaft 1 R...

Page 1952: ...pulled off the drive shaft with a wire hook if the spiral tensioning spring should jump down when removing the sealing ring 4 Pull out sealing ring by screwing in the hexagon head bolt top of page In...

Page 1953: ...as the mounting face 4 Install guide tube and tighten the fastening screws Tightening torque 10 Nm 7 5 ftlb Note The guide tube fastening screws are micro encapsulated therefore replace screws entirel...

Page 1954: ...Guide tube for release bearing on transmission housing M6x14 10 996840 996841 einordnung Tightening torques 1891...

Page 1955: ...Special tool universal master gauge VW 385 30 D Final dimension plate Special tool final dimension plate VW 385 17 E Dial gauge Commercially available Handbuch Werkstattausr stung Kapitel 2 4 Nr 136 F...

Page 1956: ...e of adjustment operations If the pinion shaft and crown wheel have to be adjusted it is best to follow the sequence below in the interest of rational working 1 Determine the total disc thickness S1 S...

Page 1957: ...kwards as far as possible and read the play off the dial gauge Example 1 00 mm Note The measured play plus the specified bearing pretension of 0 to 0 07 mm indicate the thickness of disc S4 Example 1...

Page 1958: ...Shift into 4th gear 3 Block the input shaft with special tool retaining device 9253 4 Push special tool assembly sleeve 9263 A and discs Part No 950 302 296 03 B on to the output shaft 5 Screw collar...

Page 1959: ...ng screw over the spindle into the bearing shells It should just be possible to turn the measuring mandrel by hand 14 Turn the measuring mandrel carefully back and forth until the reversing point on t...

Page 1960: ...mining total disc thickness S1 S2 1 Remove the tensioning plate with the input and output shafts 2 Insert 2 discs S1 and S2 with a thickness of 2 5 mm each into the differential and mount the tapered...

Page 1961: ...g shim S1 must be 1 4 mm thicker than adjusting shim S2 Example disc thickness S1 6 15 mm 2 0 7 mm 2 375 mm Example disc thickness S2 6 15 mm 2 0 7 mm 3 775 mm Note As the adjusting shims are availabl...

Page 1962: ...ear set 34 35 37 Disassembling and assembling transmission 4 Screw collar nut on to the output shaft Tightening torque 300 Nm 222 ftlb 5 Install the differential and mount the side transmission cover...

Page 1963: ...urn the crown wheel as far as it will go via the clamping screw of the special tool adjustment device VW 521 4 and set the dial gauge to zero 12 Turn the crown wheel back and read off the circumferent...

Page 1964: ...flange Installing sealing ring for halfshaft flange Tightening torques top of page Tools Item Designation of the special tool Remarks Pressure piece Special tool Pressure piece 9252 top of page Removi...

Page 1965: ...ge Installing sealing ring for halfshaft flange 1 Fill the space between the dust and sealing lips with grease e g Liqui Moly and drive in the sealing ring up to the mounting face with special tool pr...

Page 1966: ...ightening torques Location Thread Tightening torque Nm ftlb Halfshaft flange fastening screw M10 44 Halfshaft flange on drive shaft M10 81 996840 996841 einordnung Installing sealing ring for halfshaf...

Page 1967: ...page Tools Item Designation of the special tool Explanation A Pressure piece Special tool Pressure piece 9247 4 B Pressure piece Special tool Pressure piece 3062 C Pressure piece Special tool Pressure...

Page 1968: ...bolt 2 2 Halfshaft flange 2 3 Hexagon head bolt 12 4 Cover for final drive 1 5 O ring 1 6 Differential lock 1 7 Shaft seal 2 8 Bearing outer race 1 9 Bearing outer race 1 10 Transmission housing 1 top...

Page 1969: ...page Installing diffential and differential lock 1 Insert differential 2 Insert cover with new lightly oiled O ring no 5 in overview and screw in hexagon head bolts Tightening torque 25 Nm 18 5 ftlb...

Page 1970: ...orques top of page Tools Item Designation of the special tool Explanation A Connecting piece Shop made flat steel 6 x 18 B Pressure piece Special tool pressure piece P263 C Pressure piece Special tool...

Page 1971: ...Adjusting shim X 3 Small inner race of tapered roller bearing 1 4 Adjusting shim X 5 Hexagon head bolt 12 6 Crown wheel 1 7 Countersunk screw 3 8 Lids 1 9 Thrust plate 2 10 Cup spring 2 11 Outer discs...

Page 1972: ...amp differential lock in the vice with special tool clamping jaws 9646 3 Remove tapered roller bearing A with puller 4 Undo hexagon head bolts B and remove the crown wheel C 5 Unscrew 3 cross recess s...

Page 1973: ...ts the thickness of the adjusting shim no 2 in overview must be redetermined 39 08 15 Adusting drive set GT2 5 Now measure the basic locking torque by holding one of the halfshaft flanges in position...

Page 1974: ...996840 996841 einordnung Tightening torques 1911...

Page 1975: ...r and therefore must be replaced immediately Spoilers and undersides must therefore be regularly checked for damage Please inform the customers concerned about this top of page Installing front air du...

Page 1976: ...nnect the retaining clip 2 to the air duct 1 For this purpose push the three expansion rivets 3 included in the scope of delivery into the bores drilled in the bracket and the air duct two from above...

Page 1977: ...contrast to this at the start of production steel brake discs and brake pads are used at first The pad backing plates rear side of the brake pads must not be greased 2 vibration dampers arrows are fi...

Page 1978: ...al installation danger of damage to brake discs Use assembly aids assembly pins in order to exclude any possibility of heavy contact of the wheel with the brake disc The assembly aids 2 assembly pins...

Page 1979: ...used if there are only scrape marks on the plastic part of the warning contact If necessary remove some brake fluid by suction from the brake fluid reservoir brake fluid may escape over the rim of th...

Page 1980: ...re installation of the brake pads check the wear of the brake discs Checking front PCCB brake discs wear assessment 2 If necessary press back the piston to its original position using the resetting fi...

Page 1981: ...s 9 Check and if necessary correct the brake fluid level Bedding in the brake pads New brake pads require a slightly longer bedding in period for PCCB brake discs than cast iron brake discs In general...

Page 1982: ...contrast to this at the start of production steel brake discs and brake pads are used at first The pad backing plates rear side of the brake pads must not be greased 2 vibration dampers arrows are fi...

Page 1983: ...wheel bolts into the wheel hub before wheel removal installation During removal first remove the three remaining wheel bolts and remove the wheel carefully without touching the brake discs 2 Remove th...

Page 1984: ...brake caliper Fit new expanding spring new retaining pin and new retainer safety bracket on the brake caliper Note Ensure correct brake pad quality Use brake pads as per Spare Parts Catalogue The pad...

Page 1985: ...evel Bedding in the brake pads New brake pads require a slightly longer bedding in period for PCCB brake discs than cast iron brake discs In general the following applies New brake pads must be worn i...

Page 1986: ...allation During removal first remove the three remaining wheel bolts and remove the wheel carefully without touching the brake discs 2 Subsequently after the wheel is disassembled remove the 2 assembl...

Page 1987: ...ing It is essential that the tightening torque of the 10 screws is not changed do not turn the screws as this will have a negative effect on the sound behaviour 1 Brake disc 2 Brake disc chamber 3 Scr...

Page 1988: ...ning torque of the fastening screws 85 Nm 63 ftlb 6 Mount wheel For a wheel installation 2 assembly aids assembly pins must be screwed into the wheel hub Note on bedding in the new brake pads New brak...

Page 1989: ...installation During removal first remove the 3 remaining wheel bolts and remove the wheel carefully without touching the brake discs 2 Subsequently after the wheel is disassembled remove the 2 assembl...

Page 1990: ...he compression in the bushing It is essential that the tightening torque of the 10 screws is not changed do not turn the screws as this will have a negative effect on the sound behaviour 1 Brake disc...

Page 1991: ...For a wheel installation 2 assembly aids assembly pins must be screwed into the wheel hub Note on bedding in the new brake pads New brake pads require a slightly longer bedding in period for PCCB bra...

Page 1992: ...supplied 1 litre 000 043 203 66 Container quantity 30 litres 000 043 203 67 top of page Bleeding brakes CAUTION For vehicles with extremely high mileage or for very old vehicles damage to the brake ma...

Page 1993: ...lic unit do the following while bleeding Open the right rear bleeder valves then fully depress the brake pedal several times Hold for 2 3 seconds after each depression then release slowly Repeat this...

Page 1994: ...9105 C Retaining device Special tool Retaining device 9253 D Threaded piece Special tool Threaded piece VW 771 15 E Pressure pieces Special tool Pressure pieces 9656 F Two armed extractor span 250 Co...

Page 1995: ...electric cable 5 Remove hose A between oil cooler and transmission housing 6 Remove oil cooler To do this undo screws B and lift oil cooler up and off 7 Remove the oil pump To do this remove screws Sc...

Page 1996: ...ller bearing 1 3 Thrust plate 1 4 Loose gearwheel reverse gear 1 5 Synchronising ring 1 6 Needle roller bearing 1 7 Bearing inner race 1 8 Shift collar 1 9 Washer 2 10 Hexagon head bolt 2 11 Shift for...

Page 1997: ...le roller bearing 1 29 Bearing inner race 1 30 Thrust plate 1 31 Hexagon nut self locking 1 32 Bearing inner race 1 33 Fixed gearwheel reverse gear 1 34 Spacer sleeve 1 35 Fixed gear wheel 5th gear 1...

Page 1998: ...move complete synchonization 11 Remove fixed gear wheel 5th gear no 35 in overview and the spacer sleeve no 34 in overview 12 Remove loose gearwheel 5th gear no 16 in overview with needle roller beari...

Page 1999: ...rical roller bearing 1 2 Thrust plate 1 3 Loose gear wheel 1st gear 1 4 Friction ring 1 5 Tapered ring 1 6 Synchronising ring 1 7 Needle roller bearing 1 8 Bearing inner race 1 9 Shift collar 1 10 Gui...

Page 2000: ...g 1 33 Screw plug 4 34 Spring 4 35 Ball 4 36 Adjusting shim S3 X 37 Transmission housing 1 38 Oil pump drive wheel 1 39 Fixed gearwheel 4th gear 1 Removing shafts 1 Unscrew screw plugs no 33 in overvi...

Page 2001: ...ic disassembly of the synchronisation in assembled state may be recommendable as loss of the small parts can then be avoided 8 Unscrew nuts no 30 in overview and remove tensioning plate no 29 in overv...

Page 2002: ...1 and 2 in overview from shaft Note the quantity and thickness for reinstallation 2 Press cylindrical roller bearing no 6 in overview off with bearing inner race no 5 and 3 in overview and four point...

Page 2003: ...g inner race 1 4 Four point bearing 1 5 Tensioning plate 1 6 Bearing inner race 1 7 Shift rod 3rd 4th gear shift fork 1 8 Locking element 1 9 Thrust plate 1 10 Loose gear wheel 4th gear 1 11 Synchroni...

Page 2004: ...ssembling shaft 1 Clamp complete shaft into the vice with gear set and special tool socket wrench insert 9282 2 Remove fastening nut 3 Press off loose gearwheel for 3rd gear no 20 in overview with syn...

Page 2005: ...set Fitting front transmission case cover top of page Tools Item Designation of the special tool Explanation A Retaining device Special tool Retaining device 9253 B Socket wrench insert Special tool...

Page 2006: ...wheels and measuring the gap A with a feeler gauge Installation dimension new min 0 9 mm Wear dimension 0 6 0 7 mm 4 Push needle roller bearing no 21 in overview 3rd gear loose gearwheel no 20 in over...

Page 2007: ...aring no 6 in overview to 120 C and push onto output shaft 2 Heat bearing inner race no 5 in overview to 120 C and push onto output shaft 3 Push on four point bearing no 4 in overview onto output shaf...

Page 2008: ...o 21 in overview onto the output shaft The large collar faces the thrust plate 7 Push thrust plate onto the output shaft 8 Heat bearing inner race no 19 in overview to 120 C and push onto output shaft...

Page 2009: ...respect to the recesses in the guide sleeve 15 When setting the shift collar in place ensure that the dotting marks on the shift collar are centred with respect to the recesses in the guide sleeve 1...

Page 2010: ...lete 1 Shift rod for 3rd 4th gear 2 Locking element short 3 Shift rod for 5th 6th gear 4 Intermediate lock 5 Locking element long 6 Reverse gear shift rod 7 Intermediate lock 8 Locking element short 9...

Page 2011: ...s Location Thread Tightening torque Nm ftlb Gear housing fastening screws M 8 23 Plug screw M 10 x 1 15 top of page Assembling front gear set Note The overview diagram of the front gear set is provide...

Page 2012: ...26 in overview Note The dotting marks on the shift collar must be centred with respect to the recesses in the guide sleeve 8 Place synchronisation with shift fork no 25 in overview onto output shaft 9...

Page 2013: ...input shaft 20 Tighten new self locking nuts no 31 in overview on input shaft Tightening torque 200 Nm 148 ftlb 21 Place thrust plate no 3 in overview onto output shaft 22 Heat cylindrical roller bear...

Page 2014: ...ead bolt 10 Nm 7 5 ftlb Tightening torque for hexagon head bolt 23 Nm 17 ftlb 4 Fit connecting hose for oil cooler housing 5 Fit electric cable 6 Fill with transmission oil 34 01 55 Change transmissio...

Page 2015: ...ge Removing front ABS lead Remove front wheel Removing and installing the wheel Turbo and GT2 Remove front wheel housing liner 6 505619 Removing and installing front wheel housing liner Remove cowl pa...

Page 2016: ...ows B and remove the lead arrow C 5 Remove fabric tape D Note When cutting off the ABS lead make sure that the length of lead in the interior is sufficient for attaching the new lead 6 Cut off the lea...

Page 2017: ...ss the lead into the holders arrow A by inserting the rubber sleeves 5 Secure lead for headlight beam adjustment to the ABS lead using fabric tape B 6 Position the lead in installation position arrows...

Page 2018: ...gun It is essential that all leads are watertight Wrap commercially available PVC tape all around the area of the connection points 9 Secure the repair area to the adjacent wiring harnesses using tie...

Page 2019: ...50 30 19 Removing and installing air guide GT2 Removing and installing air guide top of page Removing and installing air guide 50 30 19 Removing and installing air guide GT2 1956...

Page 2020: ...Removing air guide Pull air guide 1 out of the lines A und B Installing air guide Push air guide 1 on to the lines A und B 996840 996841 einordnung Removing and installing air guide 1957...

Page 2021: ...55 90 19 Removing and installing rear lid GT2 Removing and installing rear lid top of page Removing and installing rear lid 55 90 19 Removing and installing rear lid GT2 1958...

Page 2022: ...cable retainer 2 Remove electrical wire Insert the electrical wire into the cable retainer 2 and close the cable retainer Ensure that the lugs have engaged correctly 3 Fastening screws 4 Unscrew fast...

Page 2023: ...996840 996841 einordnung Removing and installing rear lid 1960...

Page 2024: ...55 90 37 Disassembling and assembling rear lid GT2 Disassembling rear lid Assembling rear lid top of page Disassembling rear lid 55 90 37 Disassembling and assembling rear lid GT2 1961...

Page 2025: ...rubber cover 4 Pull rubber cover 4 out of the rear lid 3 Remove adjusting element Unscrew rubber pad 5 and disengage collar 6 4 Remove upper part of lock 8 Unscrew fastening screws 7 and remove upper...

Page 2026: ...12 7 Remove air guide 14 Unscrew fastening screws 13 and remove air guide 14 8 Remove air guide 16 Unscrew fastening screw 15 from the air guide 16 9 Remove bracket 19 Unscrew the fastening nuts 18 an...

Page 2027: ...left and right 19 for the mounting point of the rear spoiler fork 20 1 Place the rear spoiler on the rear lid Ensure that the pegs A of the rear spoiler fork 20 are guided into the bracket 19 If nece...

Page 2028: ...ightening torque 10 Nm 7 5 ftlb 3 Install air guide 13 Screw the air guide 13 into place on the inside of the lid with the fastening screws 14 Make sure that the seal 14A is fitted all around the air...

Page 2029: ...close and open the lid Determine the thickness of the plasticine and screw the rubber pad in or out accordingly Diagram body gap dimensions 8 Install rubber cover 4 Press the rubber cover 4 into the r...

Page 2030: ...wrap 2 Additional brake light 1 Disengage the cover at the side unlock lock in direction of arrow Remove brake light and disconnect the plug connection Connect the plug and insert the brake light Lock...

Page 2031: ...out of the mount compartment lighting and B for the engine compartment fan Push the plug A with the grommet through the opening in the rear lid until the grommet can be pushed into place 996840 99684...

Page 2032: ...63 15 19 Removing and installing front spoiler GT2 Removing front spoiler Installing front spoiler top of page Removing front spoiler 63 15 19 Removing and installing front spoiler GT2 1969...

Page 2033: ...ndicator light arrow A at the sides with a screwdriver and take out the direction indicator light 5 disconnect electrical plug connection 3 Undo front spoiler at the sides On the front spoiler undo th...

Page 2034: ...d out of the front spoiler 2 Fit front spoiler on the underbody Position front spoiler on the underbody and screw in place with the fastening screws 10 3 Fit front spoiler at the sides Affix front spo...

Page 2035: ...ection indicator light 5 Insert lug arrow of the direction indicator light into the front end 1 and clip into the sheetmetal clip Install wheel housing liner 505619 Removing and installing wheel housi...

Page 2036: ...37 Disassembling and assembling front spoiler GT2 Disassembling front spoiler Installing front spoiler top of page Disassembling front spoiler 63 15 37 Disassembling and assembling front spoiler GT2...

Page 2037: ...Unscrew fastening screws 5 from the air outlet frame 6 4 Remove frame centre 9 Carefully press the spring nut 8 out of the pegs of the front end 1 on the top side using a screwdriver The spring nuts 8...

Page 2038: ...nstructions 1 Undo fastening screws 3 Undo fastening screws 4 from the front spoiler 1 and the wheel housing liner 2 at the sides 2 Remove front spoiler 1 Press in the lugs with a screwdriver at the s...

Page 2039: ...pegs of the front end 1 Press the spring nut 8 on to the pegs of the front end 1 3 Install air outlet frame 6 Check and if necessary replace sheetmetal nuts 7 Position air outlet frame 6 on the front...

Page 2040: ...he groove of the front end Make sure that all lugs are engaged 2 Tighten front spoiler 1 Place the sheetmetal nut 5 in position on the front end Use the fastening screws 4 and spacer sleeves 3 to tigh...

Page 2041: ...996840 996841 einordnung Installing front spoiler 1978...

Page 2042: ...66 58 19 Removing and installing rear spoiler GT2 Removing rear spoiler Installing rear spoiler top of page Removing rear spoiler 66 58 19 Removing and installing rear spoiler GT2 1979...

Page 2043: ...frame 2 Unscrew fastening screw 1 Guide covering frame 2 out 2 Undo fastening screws 3 Unscrew fastening screws 3 by approx 5 turns Open the rear lid Only remove the rear spoiler with the rear lid ope...

Page 2044: ...he lowest horizontal position for street use Changes to the setting to individually match the personal driving style are only intended for the racing track The wing tilt may be adjusted from 1 to max...

Page 2045: ...ng and assembling rear lid 3 Tighten the fastening screws 3 and the clamping piece 4 Tightening torque 23 17 2 Fit fastening screws 3 Position the clamping piece 4 and tighten the clamping piece with...

Page 2046: ...996840 996841 einordnung Replacing rear spoiler fork 1983...

Page 2047: ...Removing roll over bar Installing the roll over bar Adjusting the roll over bar Assembly instructions for the rear trim the floor covering and the closure caps top of page Removing roll over bar 69 72...

Page 2048: ...nection Undo the lock nut 1 of the adjusting element 2 in the direction of the arrow X Relieve the tension on the right and left sections A pillar support A B by screwing in above the adjusting elemen...

Page 2049: ...nderbody Unscrew fastening nuts 5 and washer 6 from the left section A pillar support B 5 Detach left section A pillar support B Unscrew the fastening screws 3 from the left section A pillar support B...

Page 2050: ...e right spring strut mount 1 Carry out a test drive after performing assembly work on the roll over bar spring strut mount threaded parts on the body and then re tighten the fastening nuts three per s...

Page 2051: ...dy and then re tighten the fastening nuts 7 with the correct tightening torque Note Initially screw in and centre all the fastening screws and fastening nuts only in the sections A B D E and in the ba...

Page 2052: ...k on the roll over bar spring strut mount threaded parts on the body and then re tighten the fastening nuts three per side to the torque 46 Nm 34 ftlb 3 Install base cage on right of vehicle floor Pos...

Page 2053: ...o place on the screwed points of the base cage C with the fastening screws 3 Tightening torque 23 Nm 17 ftlb 8 Install left section A pillar support B Guide the left section A pillar support B inwards...

Page 2054: ...justing the roll over bar The foam coating of the A pillar support sections must be pressed against the cowl panel frame trim 1 Unscrew the adjusting element 2 in the direction of the arrow Y until th...

Page 2055: ...flaps in the floor covering 2 Press in the flaps in the floor covering 2 around the roll over bar A B C A Closure caps 3 4 In order to install the roll over bar the closure caps 3 should be removed fr...

Page 2056: ...emoving and installing bucket seat GT2 as of MY 2001 Removing bucket seat GT2 Installing bucket seat GT2 top of page Removing bucket seat GT2 72 01 19 Removing and installing bucket seat GT2 as of MY...

Page 2057: ...ards the front 2 Undoing seat screws at front Move seat to its rear limit position and undo the front M10 x 28 Torx screws 3 from the right and left seat rails using an E 12 socket wrench insert 3 Und...

Page 2058: ...48 ftlb 2 Fitting seat screws at front Move seat to rear limit position and screw the front M10 x 28 Torx screws 3 into the seat baseframe on the left and right using the E12 wrench socket and tighten...

Page 2059: ...ull six point seat belt through the upper openings in the backrest from behind arrow A and through the openings in the seat frame from the side arrow B 3 Fitting belt fitting Position foam part 4 and...

Page 2060: ...the direction of the arrow inset around the transverse strut on the roll cage into the adjustible slider The projection dimension X of the belt strap must be at least 100 mm b Roll up the projecting b...

Page 2061: ...e inner EMERGENCY STOP switch Operating the main battery switch Note For GT2 vehicles in the Club Sport model a main battery relay can be retrofitted with an EMERGENCY STOP switch inside The outer EME...

Page 2062: ...ll for relatively long periods in the Racing track status with the EMERGENCY STOP switches actuated The main battery relay is installed to the right of the battery in conjunction with a battery of max...

Page 2063: ...of the jumper plug and the wiring harness secured with tie wrap is located under the right cowl panel cover in the area of the right dome strut Cut the tie wrap with side cutters Disconnect the 6 pin...

Page 2064: ...relevant cover back into place top of page Removing the main battery relay Note After the removal of the main battery relay and switching off using the inner outer EMERGENCY STOP switch the Work inst...

Page 2065: ...cable from the relay terminal 88a to the bulkhead body ground point and remove 8 Screw the battery ground cable fitted upon delivery to the bulkhead body tightening torque 20 Nm 15 ftlb 9 Unscrew the...

Page 2066: ...spatula 2 Disconnect the 3 pin plug connection connected to the EMERGENCY STOP switch from the wiring harness by pushing and pulling Insert the wiring harness which is marked with a white identificati...

Page 2067: ...l cover standard press forwards switch position On The EMERGENCY STOP switch is actuated with the red pull loop which can be disengaged and laid towards the outside under the rear edge of the luggage...

Page 2068: ...tion of the main battery relay and switching off using the inner outer EMERGENCY STOP switch the Work instructions after disconnecting the battery 9 1 General described in Chapter 9 must be observed 9...

Page 2069: ...ar closing panel Carrera 4S Cutting out rear closing panel Inserting rear closing panel Tools and materials A closing panel top of page Cutting out rear closing panel 53 05 55 Replacing rear closing p...

Page 2070: ...or raising vehicles Safety instructions for welding Safety instructions for sticking Safety instructions for installation work Safety instructions for corrosion protection General information and qual...

Page 2071: ...ight 2 Separating the spot welded joint at the rear closing panel Use the spotweld cutter to separate the connection between the side section on the inside and the rear closing panel B C 3 Separating...

Page 2072: ...oles spaced 20mm apart for plug welding with shielding gas 2 Inserting the closing panel into the body Insert the closing panel spare part into the body and fasten it to the straightening attachments...

Page 2073: ...Tools and materials Item Tools Remarks 1 Basic straightening attachments for 911 Carrera 996 Gr 3 Workshop Equipment Manual 2 Additional straightening attachments for 996 Gr 3 Workshop Equipment Manu...

Page 2074: ...Equipment Manual 11 Hot air gun Gr 3 Workshop Equipment Manual 12 Rotary brush Gr 3 Workshop Equipment Manual 13 Spotweld cutter 7 mm no 129 Gr 2 4 Workshop Equipment Manual 996430 996431 996630 99663...

Page 2075: ...53 69 19 Removing and installing rear wheel housing liners Carrera 4S 53 69 19 Removing and installing rear wheel housing liners Carrera 4S 2012...

Page 2076: ...5 Unscrew Inspect and replace if necessary 4 Sheetmetal nut 2 Inspect and replace if necessary Removing and installing frame with heat shield see 635019 Additional assembly instructions for installat...

Page 2077: ...55 90 19 Removing and installing rear lid Carrera 4S 55 90 19 Removing and installing rear lid Carrera 4S 2014...

Page 2078: ...in the electrical plug connection 2 Fastening screws 4 Unscrew fastening screws Tightening torque 10 Nm 7 5 ftlb 3 Rear lid 1 Adjust lid to the hinges in accordance with the contours of the wings and...

Page 2079: ...and installing additional brake light Installing rubber covering Cabriolet Removing and installing reflector cover Removing and installing wiring harness Replacing the model logo Test and adjustment...

Page 2080: ...ic plugs 1 using a small screwdriver Unscrew the clamping screws 2 by turning 2 or 3 times Lift off upper part of the spoiler 3 2 Removing the folding wall from the upper part of the spoiler 1 Press o...

Page 2081: ...e rear 4 Removing the lower part of the spoiler 5 Removing and installing additional brake light 6 Unscrew the fastening nuts 9 from the upper part of the spoiler and the hinge 11 Remove the threaded...

Page 2082: ...ews 21 and remove upper part of lock 22 10 Removing fan with fan housing Disconnect plug connections for fan and engine compartment lighting on the fan housing See Removing and installing wiring harne...

Page 2083: ...Connect plugs for fan and engine compartment lighting on the fan housing See Removing and installing wiring harness 4 Fitting upper part of the lock Position upper part of the lock 22 and fasten with...

Page 2084: ...ge Position hinge 11 and screw in using the fastening screws 14 Tightening torques 9 Mounting the lower part of the spoiler 1 Position the spacer 13 on the lower part of the spoiler Tighten the fasten...

Page 2085: ...nding rivets 4 12 Mounting the upper part of the spoiler 7 Adjust the clamping screws to dimension X 8 mm 8 Place the upper part of the spoiler 3 on the lower part of the spoiler Ensure that the locki...

Page 2086: ...ber covering Cabriolet Fitting rubber covering 1 Clean bonding surface with cleaning agent Materials and tools 2 Pull off protective film A on rubber covering 18 3 Position rubber covering 18 on the d...

Page 2087: ...nect plug connection B for fan on fan housing Disconnect plug connection for engine compartment lighting C Press the fastening clips arrows together from the inner side of the mount and and remove Ins...

Page 2088: ...g arrow of the logo S top of page Test and adjustment values Note Illustration of the gap dimensions Gap dimensions body rear ndash Carrera 4S Designation Dimension Note Rear lid to rear trim H 5 2 mm...

Page 2089: ...ing screws of hinge on rear cover 14 M6 10 7 5 Nm ftlb Fastening screws of mount on rear cover 15 16 M6 10 7 5 Nm ftlb Fastening screws of upper part of lock on rear cover 21 M6 10 7 5 Nm ftlb Fasteni...

Page 2090: ...55 91 19 Removing and installing rear lid hinges Carrera 4S 55 91 19 Removing and installing rear lid hinges Carrera 4S 2027...

Page 2091: ...ft right 2 4 Collar nut M6 4 Tightening torque 10 Nm 7 5 ftlb 5 Lid hinge right 1 Loosen collar nut 4 Adjust to the right side section in accordance with lid contour 6 Lid hinge left 1 Loosen collar n...

Page 2092: ...996430 996431 einordnung 55 91 19 Removing and installing rear lid hinges Carrera 4S 2029...

Page 2093: ...lation overview of the coolant regulator Item Designation of the special tool Explanation Assembly aid Refer to Workshop Equipment Manual Chapter 2 2 No 9627 To change the coolant regulator top of pag...

Page 2094: ...1 Drain coolant 2 Remove closure cap 3 Remove coolant regulator housing 4 Remove coolant regulator 1 Drain coolant a einordnung Removal overview of the coolant regulator 2031...

Page 2095: ...oil extraction pump of the cylinder bank 1 to 3 To do this remove the three hexagon head bolts and remove the closure cap 3 Remove coolant hose Unclip the coolant hose on the housing of the coolant r...

Page 2096: ...tmetal edges as shown Push the assembly aid against the spring force until the retaining bracket is released f Turn coolant regulator by approx 90 and take coolant regulator out of the housing top of...

Page 2097: ...olant regulator 2 Install coolant regulator housing 3 Push on coolant hose 4 Install closure cap 5 Bleed coolant circuit 1 Install coolant regulator einordnung Installation overview of the coolant reg...

Page 2098: ...Position coolant regulator housing with a new seal e Tighten the three fastening screws arrow Tightening torque 10 Nm 7 5 ftlb 3 Push on coolant hose f Insert retaining clip g Push the coolant hose w...

Page 2099: ...losure cap arrow evenly by hand m Ensure that the fastening holes overlap n Tighten the three fastening screws Tightening torque 10 Nm 7 5 ftlb 5 Bleed coolant circuit Bleed the coolant circuit carefu...

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Porsche 996 TT, Repair Manual

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