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Страница 1: ...TechnicalManual 9 1 1 7 996 Technicallnformation Contents Group9 Electrics WKD483 721 www WorkshopManuals co uk ...
Страница 2: ...ineelectronics 3 Transmission manualtransmission 3 Transmission automatictransmission 4 Runninggear 5 Body 6 Body equipment exterior 7 Body equipment interior 8 9 Air conditioning Electrics 9 Circuit diagrams part 1 upto and includingthe 99 model 5 9 Circuit diagrams part 2 as of the 00 model 6 1 Thetwo folders with Group0 are to be regardedas one folder i e file the TechnicalInformation notices o...
Страница 3: ...Table of Contents repairs General technical data Instructionson repairs As can be seen from the breakdown the publishedTechnicalInformationis in the front part of each fol der numbered accordingto the Groups TheTable of Contentsassignedto each Groupwill be peri odicallyupdated Followingthe TechnicalInformation separatedby a title page the instructionson repairs assigned according to the Groupsor b...
Страница 4: ...d valvedrive Engine Lubrication Engine Cooling 2 20 21 24 25 26 27 28 Group 2 Fuel exhaust engine electronics Fuelsupply control Exhaustsystem turbocharging Fuelsystem electronicinjection Fuel system K Jetronic Exhaustsystem Starter power supply cruise control Ignitionsystem 3 30 34 35 39 Group 3 Transmission manual transmission Clutch control Manual transmission Actuation housing Manual transmiss...
Страница 5: ...ow control Exteriorequipment Interiorequipment Passenger protection 7 70 72 74 Group 7 Body equipment interior Linings insulation Seatframes Seatupholsteries covers 8 80 85 87 88 Group 8 Air conditioning Heating Ventilation Air conditioning Auxiliaryair conditioningsystem 9 90 91 92 94 96 Group 9 Electrics Instruments alarm system Radio telephone on boardcomputer navigation Windshieldwiper andwash...
Страница 6: ...ly work on the air conditioning system Setpoints for pressures and temperatures Removing and installing pressure switch for the air conditioning system Removing and installing fluid tank Removing and installing the compressor Removing and installing the expansion valve Removing and installing the heatingjair conditioning unit Removing and installing the condenser Removing and installing the magnet...
Страница 7: ...ve M6 9 6 5ftlb M5 6 4 5 ftlb Compressor M8 23 17ftlb M8 23 17 ftlb Refrigerantline M 10 26 36 19 27ftlb Oilfiller screw Fluidtank M6 6 4 5 ftlb M8 14 10 5ftlb Flangeconnections of the refrigerant lines Note Wheninstallingthe refrigerantlines the screwconnectionsandthe a rings must be wetted with refrigerantoil The refrigerant oil must be disposed of as special category waste 8 1 8 Technical data ...
Страница 8: ...tion 1 Sealcover over the heatexchangerairtight with butyl adhesive I 2 Replacecover ifdamaged 3 The heatexchangeris connectedto the enginecooling system and coolantflows through it whenthe engineis running After re movingor installingthe heat exchanger vent the cooling system see RepairGroup19 90 97 4 Clamp shutboth heater hosesin front of the heatexchangerwith a commerciallyavailable hose clamp ...
Страница 9: ...refully do not bend 2 Unscrewfastening screws 4 ea and pull con trol module out of the dashboard 2 Engageelectricalplug connections do not jam cables 3 Pull off electrical plug connections UnclipBowdencables and pull out upwardsor detachcables LabelBowdencablesbefore removal 289 98 85 10 19 Removing and installing mechanical heating and fresh air control Printed in Germany 1997 996851 85 1 www Wor...
Страница 10: ...movesteeringwheeland loosen steering columnpanel Complywith safetyregulations whenhandlingairbag units seeRepairGroup 69 3 Undothe central screw clamp on the stee ring columnswitch from belowand pull it forwards slightly Removethe cover at the top and disconnectthe electrical plug connecti ons Removethe steeringcolumnswitch 92 97 5 Removesteering column cover 4 screws 107 96 46 97 85 15 19 Removin...
Страница 11: ... 97 7 Removeleft side nozzleand disconnect electrical plugconnection Unclipcover of sun sensoran defroster paneland remove 8 Undotheinteriormonitoring systemand disconnect theelectricalplugconnection D a 0 f 9 Removethe air guide at the bottom right Removethe passenger sairbag unit Complywith safety regulationswhenhandling airbag units see RepairGroup69 10 CD 10 Removethe front cover of the center...
Страница 12: ...move Do not damage the electrical plug connectionsor cables 113 96 Installation 1 Ensurethat the air distributor casingand air guidesare correctly positioned Engagethe electricalplug connectionsand carefullylay the electricalcables do not pinch 16 Clamp shut both heaterhoses in front of the h at exchanger with a commercially available h se clamp Disconnect the heating hoses 0 the heatexchangerand ...
Страница 13: ...wall if necessary After the current distributor is mountedon the firewall tighten ing torque 15 Nm 11 ftlb the battery cable is tightenedwith a new hexagonnutM8 Tighteningtorque 15 Nm 11 ftlb 5 The heatexchangeris connectedto the enginecooling system and coolantflows through it whenthe engineis running After removingor installingthe heating fresh air control ventthe cooling system see Repair Group...
Страница 14: ...g fresh airunit Adjusting temperature valve 1 Turntemperaturecontrol to left handstop cold Temperaturevalve closed no passage to the heatexchanger lOt M B 0 C J e 00 534 1 96 536 96 2 Engagebowdencable in the adjustinglever A Bowden cable temperaturevalve B Bowden cable footwelVdefrostvalve C Bowden cable central valve 85 11 06 Installing and adjusting bowden cables of the heating fresh air contro...
Страница 15: ...ableto the fasteningpoint 537 96 538 96 Adjustingfootwelljdefrost valve 1 Turn rotary knob for air distribution to the symbolfor thefootwell Defrosteroutlet closed no passageto the windscreen Adjusting central valve 1 Turnrotary knobfor air distributionto the symbolfor the footwell Air outletto the centre and side ventsclosed SeeFigure534 2 96 2 Engagebowdencable in the adjustinglever c J 534 2 96...
Страница 16: ...owdencableon the fasten ing point 539 96 Note Perform a function test after installingthe bowdencables Test limit position of the rotary knobsfor air distributionand adjustinglevers of the valves 85 11 06 Installing and adjusting bowden cables of the heating fresh air control Printed in Germany 1997 996851 85 9 www WorkshopManuals co uk ...
Страница 17: ...0 _0 Thefigure showsthe heating fresh airunitwhen removed 531 96 Note Whenthe housinglid is removed the blower motor is simultaneously detachedfrom its guide Holdthe blower motor and carefully remove it in downwarddirection 4 o o o d t 530 96 2 Pulloffelectricalplugconnection onthe bal lastresistorandundobothfastening screws onthehousing lid Theballastresistorandhousing lidare a spare part 532 96 ...
Страница 18: ...n 911 Carrera 996 Installation 1 Installblowermotorandfastenhousing lid 2 Tightenfasteningscrews carefully plastic hpusing 3 Engageelectrical plug connectionsand per form a functiontest www WorkshopManuals co uk ...
Страница 19: ...ating fresh air unitcan be removedin this position recircula tion Installation 1 Theremovalor installationposition of the drive motor andfresh air recirculationvalve cannotbe changed 2 Removefootwell bulkheadand right air guide Disconnectelectrical plug connectionof the drive motor and undofasteningscrew 2 Tightenfastening screw carefully plastichousing 3 Engageelectrical plug connectionand route ...
Страница 20: ...nectinghose Detach connectinghose bytwisting it off the bulb 2 Pull out bulb The bulb can be pulled out by puslhinga connectinghose of a vacuumline onto it see diagram of hose connections RepairGroup24 2 Checkfunction of the bulb 535 96 85 15 85 10 19 Removing and installing bulb for rotary blower switch Printed in Germany 1997 996851 www WorkshopManuals co uk ...
Страница 21: ... your eyes consulta physician immediately Wearrubber glovesto protect your hands 2 Whencarrying out repairs on the air condi tioningsystem the system mustbe emptied by suction andthe refrigerantmust be puri fied Chlorine free refrigerants mustalso not be allowedto escape into the atmosphereand must be disposed of correctly Dueto their chemicalcomposition different refrigerants must not be mixedwit...
Страница 22: ...87 03 17 Assembly work on the air conditioning system Service unit SECU 134 1797 87 8703 17 Assembly work on the air conditioning system 996871 Printed in Germany 1997 87 2 www WorkshopManuals co uk ...
Страница 23: ...hemanufacturer soperatingand repair instruc tions mustbe observedwhencarrying out all work on the serviceunit 8 Low pressureflange 9 High pressure flange 10 Refrigerant inlet shut offvalve 1 Refrigerant outlet shut offvalve 12 Refrigerant oil inlet shut offvalve 13 Refrigerant oil ventvalve 14 Moisture indicator 15 Oil tank vacuumflange 16 Hourmeter 17 Pilot light SUCTION END 18 Pressure switch SU...
Страница 24: ...efrigerant 6 Emptythe system by suction again Dirt and moisture must be kept out of the air con ditioningsystem s pipe system Thoroughclean liness musttherefore be ensuredduring all work Systemcomponentsmustneverbe cleanedon the insidewith hot steam Use only nitrogenfor cleaningpurposes 7 Evacuate 8 Fill Whenreplacinga component all openingsmust be closed off with suitableplugs Note Payattentionto...
Страница 25: ...eachworkstep B open A close End Suction removal start 3 SUCTION END 4 ON OFF 1 ON OFF 2 SUCTION CLEANING Pressure too high filling cylinderfull Drain off refrigerantfrom the filling cylinderinto a refrigerantbottle approx 50 87 5 87 03 17 Assembly work on the air conditioning system Printed in Germany 1997 996871 HFA 134a www WorkshopManuals co uk ...
Страница 26: ...ing start 1 ON OFF 2 SUCTION CLEANING 3 CLEANING END 4 ON OFF Pressure too high filling cylinder full OnerevolutionOPEN After approx 15 minutesCLOSED 87 6 87 03 17 Assembly work on the air conditioning system 996871 Printed in Germany 1997 www WorkshopManuals co uk ...
Страница 27: ...frigerant oil B A J r I A 1833 87 A close B open 1 ON OFF Instructions 1 opento 2 OFF then 1 CLOSED and 3 OPEN 87 7 87 03 17 Assembly work on the air conditioning system Printed in Germany 1997 996871 HFA 134a A_O OQ B 3 if 0 2 www WorkshopManuals co uk ...
Страница 28: ...0 B r B A i ij air A f 1834 87 B open A close 1 ON OFF 2 VACUUMPUMP Evacuationtime at least 15 minutes 8703 17 Assembly work on the air conditioning system 996871 Printed in Germany 1997 87 8 HFA 134a www WorkshopManuals co uk ...
Страница 29: ... Topping up with new refrigerant oil B open ON OFF 1 www WorkshopManuals co uk ...
Страница 30: ...TING 10bar Pressure8 If pressure is less than 8 bar After usingthe SECU perform internalsuctionremoval seePage 87 5 first close the handvalveson bothsuctionlines 8703 17 Assembly work on the air conditioning system 996871 Printed in Germany 1997 87 10 www WorkshopManuals co uk ...
Страница 31: ...heck the systemfor leaks 1 Removethe refrigerant by suctionusingthe serviceunit 2 Determine the refrigerant oil quantity afterthe refrigerant hasbeenremoved bysuction 3 Fillup with new refrigerantoil 4 Evacuate 5 Fillwiththe stipulated amount ofrefrigerant 6 Checkthe systemfor leaks 87 11 87 03 17 Assembly work on the air conditioning system Printed in Germany 5 1997 996871 www WorkshopManuals co ...
Страница 32: ... 60 cm3 Note In new vehicles the amount of oil removed by suction is approx 15 40 cm3 Oil removed by suction must be returned to the system Refrigerantoil removedfrom a previouslyrun air conditioningsystem may no longer be used special category waste After the refrigerant hasbeen removedby suctionand a componenthas been replaced the oil quantitymust be determinedandtopped up bythe quantityremainin...
Страница 33: ...ionon Press recirculating airbutton Settemperaturecontrol to maximumcooling Switchfresh airblowerto stage 4 Start engine Operateair conditionwhileidling Set enginespeedto 2000 rpm start of time measurement If the prescribed nominalvaluesare not reached the coolingsystem mustbe checkedfor leaksand repaired 10 u 0 5 aJ ro aJ a E aJ N N 0 C aJ C aJ U 8 6 4 2 15 20 25 Outsidetemperaturein C 30 35 40 5...
Страница 34: ...30 35 40 570 1 96 Highpressure in coldcircuitasafunctionof ambient temperature 1 8 1 7 1 6 ro Q 5 Q Q Co s 0 J 1 5 1 4 1 3 35 40 15 20 25 Outsidetemperaturein C 30 571 1 96 Lowpressurein cold circuit as a function of ambienttemperature 87 Nominal values for pressures and temperatures 9968713 Printed in Germany 1997 87 14 www WorkshopManuals co uk ...
Страница 35: ...he pressureswitch I I 2 96 4 Undoandunscrew thepressure switch Installation 1 Replacethe a ring on the pressureswitch and wet it with refrigerantoil Tightening torque 3 Nm 2 ftlb 2 Refrigerantoil removedfrom a previouslyrun air conditioningsystem mayno longer be used special category waste 87 15 87 83 19 Removing and installing pressure switch for the air conditioning system Printed in Germany 199...
Страница 36: ...y waste 3 Undothe hose clamp on the fluid tank Undo bothhexagon head bolts on the fluid tank and removethe fluid tank upwards Immediately close lineswith plugs so that they are air tight 3 96 Installation 1 Do not removeplugs until shortly before installation Replacethe O ringon the branch piece and on the refrigerant line and wetthe newO ringswith refrigerantoil 2 Tighten bothhexagon head boltson...
Страница 37: ...eand put it aside 100 97 8 Undothe front compressorfasteningscrews 2 each and carefullypull the compressor out to the front The rear fastening screw mustbe pulled outup to the refrigerantline 6 Removethe fluid of the power steeringin the supplytank until belowthe connection Removethe servo tank bayonetlock Observethe marking arrow during installa tion Seal off the connectionagainstdirt Note Therei...
Страница 38: ...ine screws M8 23 Nm 17 ftlb Note Newcompressors are filled with the required refrigerantcircuit The the individualcompone taken into account 5 Tightening torque for refrigerantline screwsM8 x 32 23 Nm 17 ftlb Usefastening screwsfrom the newcompres sor Replacea rings and wet the newrings with refrigerantoil 1 First open the cap on the high pressureside and relievethe pressure from the compres sor A...
Страница 39: ...stabilize approx 5 seconds 3 Setthe fan to max output 4 Switchon the air conditioning system AC switch and allowit to run uninterruptedfor at least 2 minutes at 1500 rpm 5 After 2 minutes uninterrupted compressor operationtime the oil distribution in the air conditioningsystem is completed andthe compressor can be run up to the max engine speed 87 34 19 Removing and installing the compressor Print...
Страница 40: ...se connections and lineswith plugs so that theyare air tight 4 Undothe expansionvalveand removeit Immediatelyclose the linesto the evaporator with plugs so that they are air tight Q C n 81 98 Installation 1 Do not removeplugs until shortlybefore installation Replacea rings and wet the new rings with refrigerantoil 2 Refrigerantoil removedfrom a previouslyrun air conditioningsystem may no longer be...
Страница 41: ...he ex pansionvalve Immediatelyclose connections and lineswith plugs so that theyare air tight 4 Removesteeringwheeland loosen steering columnpanel Complywith safetyregulations whenhandlingairbag units seeRepairGroup 69 5 Undothe central screw clamp on the steering columnswitch from belowand pull it forwards slightly Removethe cover at the top and disconnectthe electrical plug connec tions Removeth...
Страница 42: ...he interior monitoringsystem and disconnectthe electrical plug connection 11 Removethe air guide at the bottom right Removethe passenger sairbagunit Comply with safety regulationswhen handlingairbag units see RepairGroup69 12 Removethe front cover of the center console Undothe fuse holder and diagnosis plug in the left footwell 112 96 15 Removethe left air guide Onlyloosenthe defrost channel Undoa...
Страница 43: ...hoseclamp Disconnect theheating hoses onthe heatexchanger andplugthe connec tions Installation 1 Ensurethat the air distributor casingand air guidesare correctly positioned Engagethe electricalplug connectionsand carefullylay the electrical cables do not pinch 19 Undoheater air conditioning unitonthelid firewall 3 nuts Pulloffthewaterdrainage hosefromtheheater air conditioning unit 2 Complywith sa...
Страница 44: ...n the firewall tighten ing torque 15 Nm 11 ftlb the battery cable is tightenedwith a new hexagonnutM8 Tighteningtorque 15 Nm 11 ftlb 5 Replacethe a rings for the refrigerantlines at the expansionvalve and wet the newa rings with refrigerantoil Note If the heatingjair conditioningunitis replaced the refrigerantoil in the evaporator mustbe top ped up Determinethe quantityof the refrigerant oil andfi...
Страница 45: ...ir guide 14 Nm 10 5 ftlb 4 0 t 0 5 Nm 3 0 t 0 5 ftlb 4 0 t 0 5 Nm 3 0 t 0 5 ftlb 4 Undothe refrigerantline on the condenser Immediatelyclose connectionsand lineswith plugs so that they are air tight Whenlooseningor tighteningthe M8 refrigerant lineson the condenser alwayscounterwith a 21 mm open ended wrench 5 Undothe fastening screws 2 screws from the condenserand pull the condenserto the side ou...
Страница 46: ...stall the Seeger circlip ring The slanted surface arrow of the Seeger circlip ring faces upwards to the fastening screw 3 Usestandard Seegercirclipringpliersto remove the Seeger circlipring Manually remo vethe beltpulley 4 Unscrewthe cable of the magneticcoil from the compressorhousing Removethe Seeger circlip ring Removethe magneticcoil from the compressorhousing 1930 87 87 27 19 Removing and ins...
Страница 47: ... measureup to the pressureplate Apply batteryvoltageto the magneticcouplingand measurethe distance air gap to the attracted pressure plate Alwaysmeasure at at leastthree points on the pressure plate in order to obtaina meanvalue Distance 0 5 mm 0 15 mm 3 Ifthe air gap is not in the tolerancerange it must be adjustedwith the aid of the spacer washers 87 27 19 Removing and installing the magnetic co...
Страница 48: ... the adjustinglevertogether and disengagethe deflectionlever Drive motor for temperature valve 3 Unscrewdrive motor of the heating air con ditioningunitand disconnectthe electrical plug connection Drive motor for footwelljdefrost 549 96 Drive motor for central valve 552 96 1 Unscrew drivemotorwithbracket fromthe heatingjair conditioning unit 2screws 2 Swiveldrive motor to the side and disengage th...
Страница 49: ...rewscarefully plastichousing 3 Engage electricalplugconnections androute wirecarefully 4 Perform functiontestafterinstallation ofthe drivemotors 87 34 87 20 19 Removing and installing drive motors of the heating air conditioning unit 9968733 Printed in Germany 1997 www WorkshopManuals co uk ...
Страница 50: ...fresh air recirculationvalve cannotbe changed 2 Ensurethat the deflectionlever of the outside air valveis seatedcorrectly 2 Removefootwell bulkheadand right air guide Disconnectelectrical plug connectionof the drive motor and undofasteningscrew 3 Tightenfastening screw carefully plastichousing 3 Disengagepivotpin on the adjustingleverwith a screwdriver 4 Engageelectrical plug connectionand route w...
Страница 51: ...culation valve Installation 1 Placetemperaturesensor on the intake duct andturn by 900 tighten 2 Engageelectricalplug connectionand route wire carefully 2 Pull off electrical plug connectionon the outsidetemperaturesensor Turntemperature sensor by 900 and pull it out 3 Installdrive motor for fresh air recirculation valveand perform a functiontest 607 1 96 87 37 87 59 19 Removing and installing out...
Страница 52: ...Torx screws of the right side ventand carefullypullthe side vent out of the dashboard OneTorx screwis located behind the cover 2 The cover simultaneouslyservesasthe intake grille for the fan and must not be closedoff 2 Press locking tabs together slightlyand re movetemperature sensorfrom the dashboard 608 96 3 Pull off electrical plug connection 87 39 87 82 19 Removing and installing interior temp...
Страница 53: ...Installation 1 Positiontemperaturesensoron the heating air conditioningunithousingandturn by 900 tighten 2 Turn blower outlet sensor by 900 and pull it out 2 Engageelectricalplug connectionand route wire carefully q Jz w 609 96 3 Pullelectrical plug connectionoff blower outlet sensor 87 41 87 58 19 Removing and installing footwell blower outlet sensor Printed in Germany 1997 9968733 www WorkshopMa...
Страница 54: ...e electrical plug connectionand slidethe blower driver into the upperbracket 2 Tightenfastening screw carefully plastic housing Installthe air guide andfootwell bulkhead j 3 Perform functiontestonheater fresh air blowermotor 1 I n 41 610 96 2 Pullblower driver out of the upper bracket and removein downwarddirection 3 Pulloffelectricalplugconnection 87 43 87 78 19 Removing and installing blower dri...
Страница 55: ...ningclips from the cooler and pull off the cooler bracket downwards If 617 1 96 4 Detach fanmotorfromthefanhousing and remove 1 u I 616 1 96 3 Disconnectthe electrical plug connectionand undoretainingclips from the fan housing Pull fan housingout of the holder bendingup the ventilationhose on the cooler at the same time 1 ill If 618 1 96 87 45 87 53 19 Removing and installing fan for condenser Pri...
Страница 56: ...Installation 1 Afterinstallation checkwhether thefancan rotatefreely 2 Tightenfrontwheelto thespecified torque 130 Nm 96 ftlb www WorkshopManuals co uk ...
Страница 57: ...kthe tubing with a hot air gun 1 Disconnect the batteryandcovertheterminal orbattery 2 Unclip ballastresistor from the holderfrom below 8 Carefully routethewiresand if necessary fix inplacewithplastictape 645 96 3 Cut off wires approx 30 mm behindthe old ballastresistor 4 Slideheat shrinktubing over the wires to the plug connection 2 x andto the fan mo t9r I x 5 Shorten wiresofthe newballastresist...
Страница 58: ...connect the plugconnections Engine temperature 110 DC Note Outside temperature 3 DC The following tests are performed Basic adaptationto the system must be performed with a newheating air conditioning control This is indicated by flashing of the displaysfor approx 5 to 10 secondseachtime the ignition is switchedon Basic adaptationis performedduringthe system test Displayof all segmentsin the contr...
Страница 59: ...ested via the DME All fault pathsare tested and anyfaults are stored Basic adaptationhas been completed after the systemtest The displaymust no longerflash Installing and removing heating air conditioning control 9968749 Printed in Germany 2 1997 87 02 19 87 50 www WorkshopManuals co uk ...
Страница 60: ...59_99 4 Unflip wire from the air flow sensoron the exijansiontank of the hydraulicpump 7 Removeholderfor oil filter console 2 screws M8 and M6 Just loosen lower M8 screw and lift holder out bore is slotted 5 Re ove belt pulleyfor hydraulicpumpand rerjloveoil filler necksfrom support 8 Undothe compressorfrom the console 3 screws 0 l VI f I j 060_99 6 U dofastening screwson the expansiontank 21MBscr...
Страница 61: ...rantoil from the compressoror refrige rantoil removedby suctionfrom a previously run air conditioning systemmay no longer be used special category waste Note Newcompr ssors are pressurisedand are filled with the re uired amountof oil for the refrige rantcircuit Theremainingoil quantityin the individualc mponentsmustthereforebe taken into accoun 1 First op the cap on the high pressure side and reli...
Страница 62: ... the compressor fastening screws on the console M8 screws 23 Nm 17 ftlb Fa tening screws for hydraulic pump an belt pulley expansion tank M8 screws 23 Nm 17 ftlb M6 screws 10 Nm 7 5 ftlb 10 Mount belt pulley for hydraulic pump and fit drive belt 11 F sten both hose clamps on the intake di tributor and clip in wire for the air flow s nsor 12 In tallholderfor oil filter consoleand air cl anerassembl...
Страница 63: ...allowidle speedto stabilize approx 5 seconds 3 Setthe fan to max output 4 Switchon the air conditioningsystem AGswitch and allow it to run uninterrupted for at least 2 minutes at 1500 rpm 5 After 2 minutes uninterrupted compressor operationtime the oil distribution in the air conditioningsystem is completed and the compress r can be run up to the max enginespeed Removing and installing compressor ...
Страница 64: ...TechnicalManual 9 7 996 TechnicalInformation Group9 Electrics www WorkshopManuals co uk ...
Страница 65: ...t engineelectronics 3 Transmission manualtransmission 3 Transmission automatictransmission 4 Runninggear 5 Body 6 Body equipment exterior 7 Body equipment interior 8 9 Air conditioning Electrics 9 Circuit diagrams part 1 upto and includingthe 99 model 5 9 Circuit diagrams part 2 as of the 00 model 6 1 Thetwo folders with Group0 are to be regardedas one folder i e file the TechnicalInformation noti...
Страница 66: ... Contents repairs General technical data Instructionson repairs As can be seen from the breakdown the publishedTechnicalInformationis in the front part of each fol der numbered accordingto the Groups TheTable of Contentsassignedto each Groupwill be peri odicallyupdated Followingthe TechnicalInformation separatedby a title page the instructionson repairs assigned accordingto the Groupsor brokendown...
Страница 67: ...d valvedrive Engine Lubrication Engine Cooling 2 20 21 24 25 26 27 28 Group 2 Fuel exhaust engine electronics Fuelsupply control Exhaustsystem turbocharging Fuelsystem electronicinjection Fuelsystem K Jetronic Exhaustsystem Starter power supply cruise control Ignitionsystem Group 3 3 30 34 35 39 Transmission manual transmission Clutch control Manual transmission Actuation housing Manual transmissi...
Страница 68: ...windowcontrol Exterior equipment Interior equipment Passengerprotection Group 7 7 70 72 74 Body equipment interior Linings insulation Seatframes Seatupholsteries covers Group 8 8 80 85 87 88 Air conditioning Heating Ventilation Air conditioning Auxiliary airconditioning system Group 9 9 90 91 92 94 96 Electrics Instruments alarmsystem Radio telephone on boardcomputer navigation Windshieldwiper and...
Страница 69: ...66 9260 19 9256 19 9278 19 9267 19 927219 92 1 92 3 92 5 92 7 92 9 92 11 92 13 92 15 92 17 92 19 Windshield wiper and washer system Removing and installing wiper link Removing and installing wiper blades Removing and installing wiper motor Removing and installing rear window wiper system Non adjustable spray nozzles Removing and installing tank for windscreen washer system Removing and installing ...
Страница 70: ... on Litronic headlight dipped beam Removing and installing angle sensor for automatic headlight beam adjustment Removing and installing angle sensor for automatic headlight beamadjustment Removing and installing control module for automatic headlight beam adjustment 9498 19 94 51 96 96 96 96 96 96 96 96 96 96 96 96 96 96 96 1 96 3 96 5 96 7 96 9 96 11 96 13 96 15 96 17 96 19 96 21 96 23 96 25 Ligh...
Страница 71: ...e stored in variouscontrol modulesif the battery hasbeen completelydischarged 5 Alwaysdisconnectthe battery terminals before carrying outweldingwork on the vehicle Remedy Delete the supply voltage entry from the control modules in question 6 Wiring harnessplugs of control modulesor other electronic componentsmustbe connectedor disconnectedwith the ignition off Exception vehicleswith the additional...
Страница 72: ...pedal Switch qff ignitionfor at least 10 seconds Remedy Manually close each power windowasfar as it will go then pressthe rocker switchfor closing the windowagain The limitposition of the respectivepower windowis nowstored in the control module again This completesthe adaptationof the throttle adjusting uni 90 25 Instrument cluster Thetrip counteris set to 0 whenthe power supplyis disconnected Wit...
Страница 73: ...el in the instru ent cluster will be incorrector deleted 2 Whenthe power supplyis disconnected the built nGPSreceiverlosesthe so called almanac containingthe satelliteorbital paths If the t ink containslessthan 10 I it is possible that th fuel levelwarning light is no longer activatd 3 Thedate andtime are deletedwhenthe battery is disconnected 4 Radiostationsstored by the customerare no longerdisp...
Страница 74: ...sferr d to the instrumentcluster Ifthe time is t en manuallychanged by meansof the instr ment cluster this time is adopted by the PCMand synchronisedwith GPStime 4 Thestoredstationsaredisplayed againwhen station buttons 1 to 6 arepressed 5 Thetelephoneis enabledagainwhenthe telephonePINcode is enteredwith the SIM telephonecard inserted 9 4 9 Work instructions after disconnectingthe battery 9969_1 ...
Страница 75: ...the openingsand pull off the but ton A toward the front 97 092 Note If the vehicleis equippedwith a handsfreetele phone disconnectthe microphoneplug con nectioninstead of the dummyplug 96 507 6 Detach the instrument clusterfromthe dashboard insertandremove it 3 Unclipthe collar from the dashboardinsert The hazardwarning light switch 8 is heldin the dashboardinsert bytwo lockinghooks Pressthe right...
Страница 76: ...e dashboard 2 Installha ardwarning light switch Pressbut ton A on the hazardwarning light switch 8 untilthe button is heardto engage 3 nectj ebatteryandperformafunction 90 2 90 25 19 996901 Removing and installing instrument cluster Printed in Germany 4 1997 www WorkshopManuals co uk ...
Страница 77: ... A 487_98 4 Unclipthe centre of the electronic unit at the bottom Holdthe releasedgreen guide rails outwardswith a screwdriver Takethe electronic unitupwardsout of the display unit evenly pullingalternatesides 486_98 To open the instrument cluster place it on a soft dus1 free surface Whenthe instrument cluster is open take care not to touch or damage alnydials or solder joints of the display un it...
Страница 78: ...e centre at the bottom Closethe lockingtab onthe upperpart ofthe electronic unitin the top of the front frame bracket 4 Usinga screw jriver pushthe two green guiderail inwardsoverthe contactconnector take car that they are not crooked 5 Pushthe right and left sheetmetalsprings overthefixinglugs I 6 Pushonthe adjustment buttonoftheclock and trip mileage counter Disassembling and assembling instrume...
Страница 79: ...rom below thrl3ugh the sound outlet opening Pull off electrical plug connection and observe installation position of the horn Installation 1 Observeinstallationposition of the horns The horn must nottouch the bodyor a bracket 2 Unscrew the M 6 hexagon nut from the bracket and remove the high pitch horn through the sound outlet opening 2 A toothedwasher must be fitted betweenthe horn and bracket Ti...
Страница 80: ...h the Por cheSystemTester 2 elect vehicletype 911 996 Select control modules elect instrumentcluster Select total mileage Input Vehicle Identification Number Confirmwith key F7 nputkilometre reading ICode with key F8 2 THetotalmileage is adopted inthe new in trument clusteraftercoding www WorkshopManuals co uk ...
Страница 81: ... En ine coolantleveltoo low ight flashes slowly 0 5 Hz 2 En ine compartment temperature too high ightflashes slowly 0 5 Hz enginecompartmentblower mightbe faulty 3 En ine coolant temperature too high ight is lit pointeronthe right 4 Te nperarure sensoratwateroutletfaulty ight flashesrapidly 1 Hz pointeronthe right Note The t mperaturewarningin pointthree is indic ted if the conditions enginecoolan...
Страница 82: ...10 or Motorola Position 1 free Position 2 Nokia 2110 Position 3 Motorola 2 1 3 11 97 Setting 1 Carefully uncliphandsfree microphone from thedashboard insertandpullout 2 Use a srnall screwdriverto set the position of the installedtelephonesystem e g Nokia 2110 Pos 2 The setting as deliveredin new cars is position 3 3 Carefully clipthehandsfree microphone into thedashboard insertagain 91 1 91 57 15 ...
Страница 83: ...be ta ken off in order to removea defectivesensor The sensor sare arrangedin the order outer left innerle ft inner right and outerright 410 97 409 97 The sensor with holder in the rear spoiler con sists01six parts I Collar 2 Washer 3 Sensor housing 4 Isolatin ring 5 Sensor 6 Retaining spring 91 3 91 75 19 Removing and installing sensor for ParkAssistent Printed in Germany 4 1997 996913 www Worksho...
Страница 84: ...Fitisolatingring and push sensor into the sen sor housing 2 Slideretainingspring over the sensorhousing and presson until it meets the stop 3 Engageelectricalplug connectionsand install fit rear spoiler Note The electricalplug connectionin the vehicle mustalwayspointto the centre of the vehicle Plugconnectionwith marking whiteadhesive tape on the wiring harnessalwaysconnectedto outer left sensor 4...
Страница 85: ...nectedto outer left sensor 474_98 ParkAssistent control module Note The control moduleis fastened nextto the alarmsystem centrallockingsystemcontrol moduleunderthe driver s seat Whenremoving removethe seatanddetachthe retainingplate two hexagon head screws M6 x 16 429_9 Pull off plug connection on the sensor Liftthr lower lug with your finger and pull off the plug cpnnection 130_97 91 5 91 75 19 R...
Страница 86: ...unit 2 Detacharid removethe central vent 4 Torx s rews5 0 x 22 at the centre vent Carefullypull out the displayand operator control unitand disconnectthe electrical plug connections Note The mountingpoints on the displayand operatorcontrol unitfor fastening it in the retainingbracket were modified in the current modelyear The retainingbracketwas adaptedaccordingly As the result of the modification...
Страница 87: ...d operator control unitfirst Onlythe navigationcode hasto be input again if the navigationunit is exchanged 2 After installationof a new displayand operator control unit the system must be activatedwith the PorscheSystem Tester2 Connectand switch on the Porsche SystemTester2 Switchon ignition Switchon PCM by pressingthe volume control displayremainsdark Establishcommunicationwiththe Porsche System...
Страница 88: ...nctiontest Removal 1 Unclipthe cover from the navigationunit on the left andright 2 Insertspecialtool V 160 into the recesses of the navigationunitand engage Device code input Thenavigationunitis protected againsttheft by a devicecode Onlythe navigationcode hasto be inputagain if the navigationunit is exchanged 729_97 3 Carefull push out the navigationunitrearward and disconnectplug connections 91...
Страница 89: ...plug connection and route leadcarefully 2 Installhousingwith GPSantennaand clip in cover Note TheGPSantennamust not be covered by metallicor moist objects Removal 1 Unflipcoverfrom behind andtakeout 2 Un o bothTorx T20 fastening screwswith an angledscrewdriver WARNING Fasteningscrewscould fall out p I rt ro pn J I i 73o_97 3 Re tove housingwith GPSantenna dis onnect electrical plug connection on e...
Страница 90: ...sthave a type approvalfor this vehicleand be equipped with aliie mark Porsche ha 5 providedan approvalfor mobile Phone r and radioswith a maximumtransmitter power of 1 watts in the Driver sManualof its vehicles The installationinstructionsand recommendationscontainedthere must be observed Porsche p rmits the installation and use of radio equipment over lOW for the communications services listed in...
Страница 91: ...le regulation95 54 Inthis case a subsequent examinationwill be performed by PorscheEMC expertsto ensurecompliancewith protective targets Radiosonlyachievetheir optimumrangewhen an outside aerialis used The use of mobile phonesand radios withoutor with incorrectly installedoutside aerials or defective aerials maygive rise to excessiveelectromagnetic fields in the vehicle In this case the possibilit...
Страница 92: ... sequence Distance sensor The distancesensor transmits the distancetravelledto the PCM navigationunit Thedistancesignalchanges if the circumference of the tyre changes e g tyre change This modificationmust be calibrated by the PCMnavigationunit afterwards Switchon the PCMwith a free panoramic viewfor approx 20 minutes to load GPS almanac Driveon a motorwayif possible at a speedgreater than 60 km h...
Страница 93: ... changing a tyre Drive on a motorwayif possible at a speed greater than 60 km h for a distance of approx 50 km Calibrationof the distancemeasurement Procedure after the power supply has been interrupted Switch on the PCMwith a free panoramic viewfor approx 20 minutes to load GPS almanac 911215 9969115 Adjusting calibrating PCM navigation unit Printed in Germany 23 1999 91 16 www WorkshopManuals co...
Страница 94: ...e left and right and removethe cowl panelover the wiper link 3 Removethe left dome strut Undothe wiper link on the body 3 screws M6 and discon nectthe electrical plug connectionon the wiper motor 4 1 96 2 Tightening torques q 17 Nm 12 5 ftlb 10 Nm 7 5 ftlb 0 WiperarmnutM8 Hexagon head bolts M6 i L I A 3 Beforeinstalling thedomestrut thevehicle mustbe onits wheels E 96 4 Carefullyremovethe wiper li...
Страница 95: ...ppliesto left handdrive and right handdrive vehicles Theclip installationposition mustbe observed wheninstallingthe wiper bladesfor left hand drive and right handdrive vehicles A B 143 96 A Clip for left handdrive vehicles 142 96 B Clip for right handdrive vehicles A Passenger s side B Driver s side Note The spoiler edge on the wiper bladeon the driver s side mustface downwards 92 27 19 Removing a...
Страница 96: ...er widthacross flats 21 mm Removethe link 3 Undothe fasteningscrews on the wiper motor 3 screws M6 and the lower fastening screw on the body Carefullyraise the wiper link and removethe wiper motor downwards 1 6 96 2 Connect thebattery I 3 Switchon the wiper motor and checkthe wiper position Tightening torques 5 96 Fasteningscrew motor M6 Fasteningnut link M8 Hexago headbolt M6 8 Nm 6 ftlb 17 Nm 02...
Страница 97: ...g torques HexagonnutsM6 Hexagon head bolt M6 Wiperarm nutM8 8 Nm 6ftlb 8 Nm 6 ftIb 17 Nm 12 5 ftlb 2 Removethe rear panelcover in front of the rear window wiper motor Undothe retaining frame with rear window wiper motor at the rear centre panel 2 nuts 1 screw and pull outto the front Disconnectthe electrical plug connection Note The spoiler edge on the rear window wiper blade mustface outwards 98 ...
Страница 98: ...he windscreen washer system are not adjustable Sharpobjects needles must not be inserted in the nozzleholes Do not install old and new spraynozzles together 662_97 A Old version adjustable B New version non adjustable 92 9 92 66 Non adjustable spray nozzles Printed in Germany 11 1998 996929 www WorkshopManuals co uk ...
Страница 99: ...t the headlightholder 4 Carefullypull off the hosefor the windscreen washer system 5 Undofastening screwsandswingtheholder inward 010_99 Installation 7 I tank or 3 I tank 1 Firstpush 7 I tank underthe wing at front then engageelectrical plug connectionof the pumps 009_99 2 Pushtank rearwardinto the holderand engagethe electrical plug connectionfor the fluid levelindicator 6 Pulltank forward out of...
Страница 100: ...4 Engagehosefor the headlightcleaning systemand carefullypush on the hosefor the windscreenwasher system 5 Engagefiller neck and fill in water Perform a functiontest 6 Installwheelhousingliner and mountthe left front wheel tighteningtorque 130 Nm 96 ftlb 92 60 19 92 12 Removing and installing tank for windscreen washer system 9969211 Printed in Germany 33 1999 www WorkshopManuals co uk ...
Страница 101: ...iceNo 92 60 19 2 Installpumpandtank fill inwaterandperform afunction test 2 Removehoseto the spray nozzlesat the tank andturn the pump outletto the rear 3 Lift pump upwardsout of the rubber sleeve 012_99 4 Pull hose off the pump Note A stuck hose can be pulled off more easilyif it is heatedwith a hot airgun 92 13 92 56 19 Removing and installing pump for windscreen washer system Printed in Germany...
Страница 102: ... water and perform a functiontest 2 Removehoseto the spray nozzlesat the tank and turn the pump outletto the rear 3 Removespacer betweenthe pumpsand lift pump upwardsout of the rubber sleeve 1 011_99 4 Pullhoseoffthepump Note A stuck hose can be pulled off more easilyif it is heatedwith a hot airgun 92 15 92 78 19 Removing and installing pump for headlight washing system Printed in Germany 33 1999...
Страница 103: ... refer to ServiceNo 92 60 19 Installation 1 Checkrubber sleevefor sensor replace if necessary 2 Pullsensorfor fluid levelindicator out of the tank to the side 2 Installsensorand tank fill in water and perform a functiontest 016_99 92 17 92 67 19 Removing and installing fluid level indicator Printed in Germany 33 1999 9969211 www WorkshopManuals co uk ...
Страница 104: ...e spray nozzle holder s 4 Separateplug incouplingand take outthe spraynozzle 207_99 8 Loosenhoseclamp and pull hose off the spraynozzle 206_99 5 Loosenhose clamp and pull hose off the spray nozzle Installation 1 Pushhose asfar as it will go onto the new spray nozzleandfasten the hoseclamp Note A stuck hose can be pulled off more easilyif it is heatedwith a hot airgun 2 Reinstallnewspray nozzlewith...
Страница 105: ...4 Installmain headlightand check position of the spray nozzlein the covertrim Remove the main headlightagainand centre the spray nozzleif necessary 5 Installmain headlight check it and perform a functiontest 92 20 92 72 19 Removing and installing spray nozzle for headlight washing system 9969211 Printed in Germany 33 1999 www WorkshopManuals co uk ...
Страница 106: ... openingand closingthe headlights 2 Wheninstalling pressheadlights firmlyinto thewing 3 Secure theplugsafterinstallation Note Headlightsmust not be coveredwith a front apron or foil whenswitchedon 94 1 94 15 19 Removing and installing headlights Printed in Germany 1997 996941 www WorkshopManuals co uk ...
Страница 107: ...y edge Adjustmentsshouldbe made onlyin the eventof an accident repair or replacement of head lights Adjustment instructions Note Thefasteningnuts of the adjustingcomponents are fitted at the factory as shownin Figure 293 96 293 96 353 96 ItemA Thetransitionfrom the headlighthousingto the body is in the same plane level 94 15 05 Headlights basic adjustment in the body Printed in Germany 1997 996941...
Страница 108: ...astening nutsto the same heightas the old versionandtighten slightlyby hand Figureshowsmountingplate removed J 294 96 354 96 2 Press headlighthousingfirmly into the body and lock 3 The correct adjustmentis described in items A C 4 After adjustment tightenthe fasteningnutsto 8 t 2 Nm 6 t 1 5 ftlb J The headlightwasher nozzlecan be adjustedat the holder Headlights basic adjustment in the body Printe...
Страница 109: ...own see figure Note For detailsof headlightadjustment refer to Group0 Entirevehicle General RepairGroup 03 Pages03 6 to 03 9 I jt I I I I 355 96 Before installingthe headlighthousing ensure that the headlampventis pluggedonto the plug housing 94 15 05 Headlights basic adjustment in the body Printed in Germany 1997 996941 94 5 www WorkshopManuals co uk ...
Страница 110: ...river 97 97 4 Disconnectthe electrical plug connections 5 UndoM16x 1 hexagon nutofthe lightswitch 6 Pullthe lighting unitswitch out of the side vent to the front by approx 5 mm 96 97 3 Undothree 4 0 x 18 Torx screws of the left side vent and carefullypullthe side vent out of the dashboard OneTorx screwis located in the light switch on the right 9405 19 Removing and installing main light switch Pri...
Страница 111: ...in clockwisedirection 510 96 Installation 1 Engage light switch by turning it slightly in counter clockwise direction Tightening torque of the hexagon nut M16 x 1 3 5 Nm 2 5 ftlb 2 Engage electricalplugconnections andinstall sidevent 3 Connectthe battery and perform a function test 8 www WorkshopManuals co uk ...
Страница 112: ...he drive motor plastic housing Removal 1 Removethe headlightand openthe rear co ver Disconnectthe electrical plug connection on the drivemotor 2 Undothe fastening screwand removethe drive motor byturning counter clockwise bayonetlock 74 97 J Installation Jl 1 Pressthe ball head into the ball socketand securethe drive motor byturning clockwise bayonetlock J 0 2 Securethe locking screw and snapin th...
Страница 113: ...the button there are small openingsthat project beyondthe dashboardin sert Inserttwo small screwdriversinto the openingsand pull off the button A toward the front 507 96 3 Unclipthe collar from the dashboardinsert The hazardwarning light switch 8 is heldin the dashboardinsert by two lockinghooks Pressthe right locking hooktoward the switch grip the button holderwith a pair of pliersand pull outthe...
Страница 114: ...re must be affixed in linewith the ou ter line on the right handheadlightlens refer to Figure454_97 PointsC and D on the innerline of the left handheadlightlens refer to Fig ure 455_97 The maskingfilm with the points notch A and B in the figure mustbe affixed in linewith the ou ter lineon the left handheadlightlens refer to Figure457_97 PointsC and D on the innerline of the right handheadlightlens...
Страница 115: ...ountries with left hand traffic Rightside Left side 454_97 455_97 For right hand drive vehicles in countries with right hand traffic Rightside Left side 457_97 456_97 94 15 94 15 13 Masking film for left right hand traffic Printed in Germany 4 1997 9969411 www WorkshopManuals co uk ...
Страница 116: ...ht W2 1 x 9 5 D wsw Additional brakelight W2 1 x 9 5 D W3W Number plate light SV8 5 C5W Installing bulbs Onlybulbs specified in the bulbtable may be used Bulbs with a higherwattage may cause damageto the bulbhousing To preventshort circuits the loadsin question must be switched off while bulbsare changed New bulbs must be cleanand free of grease Therefore never touch bulbs with your bare hands Use...
Страница 117: ...nection 3 Closecover and installmainheadlight Performa function test of bothbulbs A Dipped beam headlight B High beam headlight 131_98 1 Removeand installmain headlight refer to ServiceNo 94 15 19 2 Openrear cover and disconnectthe electrical plug connectionof the defectivebulb 3 Pressdown retaining bracket arrow and swivelto the side Removedefectivebulb 94 19 94 23 19 Removing and installing halo...
Страница 118: ...penthe rear closure cap and pull the parking light holder arrow out of the headlightreflector do not pull the wires 2 Closecoverandinstallheadlight Perform a function test Note Inthe case of litronic headlights the H6W bulb specifiedin the Parts Cataloguemustbe installed lj 132_98 3 Removethe faultybulb from the parking light holder 94 21 94 27 19 Removing and installing bulb for parking light Pri...
Страница 119: ...und cover in the headlight housingclockwiseand remove 2 Attach retainingbracket and engageelectrical plug connection 3 Disconnectelectrical connectionof defective bulb do not pull on the wires 3 Closecover and installmainheadlight Performa functiontest 4 Pressdown retaining bracket arrow and swiveldownwards Removedefectivebulb 100_98 94 67 19 Removing and installing bulb for fog light Printed in G...
Страница 120: ...wbulband ensurethat it is correctly seated bayonetlock 2 Turnbulbsocketcounter clockwise andremove fromthe headlight housing 2 Rotatebulb socket clockwiseand engage Installmain headlightand perform a functiontest 0 101_98 3 Takedefective bulb out of the bulb socket bayonetlock 94 56 19 Removing and installing bulb for direction indicator light Printed in Germany 8 1998 9969417 94 25 www WorkshopMa...
Страница 121: ...lation 1 Insertnewbulb in the bulb socketand install bayonetlock 2 Engageelectrical plug connectionand install direction indicatorlight Inserttabs of directionindicator light arrowA forwardsinto the wing Engageretainingspring arrowB in the wing 2 Releaseand pull off electrical plug connection Turn bulb socket counter clockwiseand remove bayonetlock 3 Remove defective bulb 102_98 3 Perform a functi...
Страница 122: ...catorlight 111_98 2 Turnbulb socketcounter clockwise and removefrom the taillight 3 Takedefectivebulb out of the bulb socket bayonetlock 307_99 2 Fastenthe holderand break off the assembly aid Installation 1 Installnewbulband ensurethat it is correctly seated bayonetlock 3 Installthe taillight andcheckthe gap dimen sion 3 mm usinga star gauge If necessary removethe taillight againand carry outfine...
Страница 123: ... 1 Insertnewbulbintheholesofthe contact springs 2 Pushthe rubber cover protects againstwater leakingin carefullyover the numberplate light andfasten 3 Performa functiontest 104_98 2 Pushback the rubber cover and remove defectivebulb from betweenthe contact springs 94 29 19 Removing and installing bulb for number plate light Printed in Germany 8 1998 9969417 94 31 www WorkshopManuals co uk ...
Страница 124: ...ove 12O_98 4 Removebulbholder andtake out defective bulb g Installation 1 Insertnewbulb in the bulb holder Engage fasteningtabs and connectelectricalplug connection 112_98 3 Disconnectelectrical plug connectionand disengageall fasteningtabs of the bulbholder 2 Insertadditionalbrake light andturn lock clockwise byapprox 90 3 Pushcorner segmentinto the lock and clip in place 4 Performa functiontest ...
Страница 125: ...ock the cover with control moduleand insert the headlighthousingin the wing Removal 1 Switchoffthelight Release the headlight housing andpullout forwards slightly 2 Engagethe electrical plug connectionof the automatic headlightbeam adjustment and lock the headlighthousingin the wing 2 Disconnectthe electrical plug connectionof the automatic headlightbeam adjustment and removethe headlighthousing 3...
Страница 126: ...to the cover and engagethe electrical plug connection Removal 1 Switchoffthelight Release the headlight housing andpullout forwardsslightly 2 Lock the cover with control moduleand insert the headlighthousingin the wing 2 Disconnectthe electrical plug connectionof the automatic headlightbeam adjustment and removethe headlighthousing 3 Engagethe electricalplug connectionof the automatic headlightbea...
Страница 127: ...l module mustbe routed between the headlighthousingandthe ignitionunit Removal 1 Switchoffthelight Release the headlight housing andpullout forwardsslightly 2 Disconnectthe electrical plug connectionof the automatic headlightbeam adjustment and removethe headlighthousing 2 Lock the cover with control moduleand insert the headlighthousingin thewing 3 Engagethe electricalplug connectionof the automa...
Страница 128: ... installedin the reflector and with the headlightinstalled 4 Remove theignition unit twofastening screws 5 Pressthe releaseleverdownwitha screwdriver and pull outthe servo motor towardsthe rear Removal 1 Switchoffthelight Release the headlight housing andpullout forwardsslightly 2 Disconnectthe electrical plug connectionof the automatic headlightbeam adjustment and removethe headlighthousing 3 Rel...
Страница 129: ... drivemotor 3 Installtheignitionunit twofastening screws 4 Lock the cover with control module and insertthe headlighthousing in the wing 5 Engagethe electrical plug connection of the automatic headlightbeam adjustmentand lock the headlight housingin the wing 6 Carryoutfunctioncheckof theheadlights 94 42 94 94 19 Removing and installing servo motor for automatic headlight beam adjustment 9969435 Pr...
Страница 130: ...changeoverlever A to positionT touristsetting The gasdischargelamp 02S lamp may onlybe operatedwhen installedin the reflector and with the headlightinstalled I r 0 Note Masking film for left right hand traffic must not be affixed to Litronic headlights These headlights incorporate a changeover lever for driving in countries with lefVright hand traffic This lever is located on the left and right on...
Страница 131: ...p may onlybe operatedwhen installedin the reflector and with the headlightinstalled Note When the dipped beam is faulty the individual components gas discharge lamp ignition unit control module of the second headlight can be exchanged Only the battery voltage with the headlight removed can be checked in the wing at the plug connection at pin 9 56 band pin 4 31 according to the circuit diagram The ...
Страница 132: ...tach theanglesensorfromtheretaining bracket andremove it 1 Installation 1 Fastenthe anglesensorto the retaining bracketand install 9 419_98 2 Engagethe electricalplug connectionand carefullypullthe rubber cover over the plug connection protects againstwater leakingin 3 Detachthe retaining bracketfor the angle sensorfrom the side memberfrom below 3 Securethe linkageto the rotary lever tighteningtor...
Страница 133: ...ter this the headlights must be readjusted using a standard 5 mm ball head screwdriver Note For details of headlightadjustment refer to Group0 Entirevehicle General RepairGroup Maintenance 03 Pages03 6 to 03 8 Removing and installing angle sensor for automatic headlight beam adjustment 9969435 Printed in Germany 18 1998 94 48 94 78 19 www WorkshopManuals co uk ...
Страница 134: ...nstwater leakingin 2 Detachthe retaining bracketfor the angle sensor combinationwire and brake line from the body 3 Secure the linkage to the rotary lever tightening torque 7 Nm 5 0 ftlb 4 Once the angle sensor has been installed the control module must be recalibrated with the Porsche System Tester 2 After this the headlights must be readjusted using a standard 5 mm ball head screwdriver e Note F...
Страница 135: ...d andrightairguide 3 After installation the control modulemustbe encodedand calibratedwith the Porsche SystemTester2 After this the headlights must be readjusted using a standard 5 mm ball head screwdriver 2 Undothe control module two sheetmetal screws from below Releasethe electrical plug connectionand take out the control module Note For details of headlightadjusb nent refer to Group0 Entirevehi...
Страница 136: ...lockhousing canbe opening inthedashb 4 Openthe locking buttonwith a short cross headscrewdriver 1 4 turn counter clockwise Pullthe signalconverter out of the holderto the rear Thefigureshowsthe signalconverter without dashboard 529 96 Installation 1 Closelockingbutton of the signalconverter housing 1 4 turn clockwise 2 Engage electrical plugconnections andinstall sidevent 3 Connect thebatteryandpe...
Страница 137: ...r fingers 2 Engagethe electrical plug connectionsand carefullylaythe electrical cables do not pinch 3 The cover lensesmust not be soiledor smudgedwith grease Clip in cover lenses again 176 97 2 Unclipsensor holder at the rear left and right arrow B pushforward towardsthe windshieldand remove Pull off electricalplug connection 3 Unclippassenger compartmentmonitoring sensor at the side and removefro...
Страница 138: ...astening screws Removing alarm siren and tilt sensor Removecover for fluid reservoir air conditioning 2 Pull off connector on the alarm siren bQ 3 Pull off connector on the tilt sensor G 4 Undonut 643_ _96 Note Electricallocking of the rear lid release has beenomitted on vehiclesmanufacturedafter March 99 Frontlid releaselocking is still carried out electrically J 1L 1 Electric lockingis carried o...
Страница 139: ...itter is operated more than 256 ti mes withoutreachingthe associatedreceiver e g vehicleoutside range or vehiclebattery disconnected the vehiclewill not recognisethe radio transmitter the nexttime it is operated If the number of operationsis less than 1024 it is possibleto perform re synchronisation as de scribed below 4 Energy saving mode active In order to keep breakdowns resultingfrom an emptyb...
Страница 140: ...ggering the alarm the vehicle key with validtransponder mustbe turned in the steering lock withinthe vehicle entering delayof 10 seconds Thisalso applies if the vehiclewas parked unlockedfor longer than five daysdueto the passivearming function automaticarming of the alarm system30 secondsafter the vehicleis left with the ignition key removed the central locking system is not activatedin this case...
Страница 141: ...Onlybulbsspecified in the bulbtable may be used Bulbswith a higherwattage may cause damageto the bulb housing To preventshort circuits the loadsin question must be switched off while bulbsare changed Newbulbs mustbe cleanandfree of grease Therefore never touch bulbs with your bare hands Use a cloth or soft paper for changingbulbs 96 9 96 22 Bulb table and installation instructions Printed in Germa...
Страница 142: ...fullyusing a screwdriver arrow Installation 1 Insertnewbulbinthebulbsocketandinstall 2 Installdoor warning light in the door trim paneland perform a functiontest i I 106_98 2 Removebulb socketfrom the door warning light and removedefective bulb 96 16 19 Removing and installing bulb for door warning light Printed in Germany 8 1998 996969 96 11 www WorkshopManuals co uk ...
Страница 143: ...t of the trim panelusing a screwdriver arrow Installation 1 Insertnewbulb in the holes of the contact springs 2 Install luggage compartment light in the trim panel and perform a function test 107_98 2 Remove defective bulbfrombetween the contactsprings 96 13 96 41 19 Removing and installing bulb for luggage compartment light Printed in Germany 8 1998 996969 www WorkshopManuals co uk ...
Страница 144: ...ectivebulb Installation 1 Insert newreadinglamp bulb in the bulb socketand install bayonetlock 3 Removeinterior light Carefullyunclip lens glass on switch side arrow and remove 2 Insertnewreadinglamp bulb in the holes of the contact springs and clip in the lensglass 3 Install interior light First insert rear side into the trim panel then press up at the front and engage 4 Performfunction test of r...
Страница 145: ...unitin the sameorder of procedure Disassemblingand assemblinginstrument cluster Servo No 90 25 37 1 Removing andinstalling instrument cluster Servo No 90 25 19 2 Undothe bulb holderwith a small crewdriver bayonetlock I I L 0 0 0 343_98 Installation 1 Installa newbulb bayonetlock 109_98 2 Assembleor installthe instrumentcluster and perform a functiontest 3 Take out the faultybulb The bulband bulb h...
Страница 146: ...t of the fan cover using a screwdriver arrow Installation 1 Insertnewbulb in the holesof the contact springs 2 Installenginecompartmentlight in the fan cover and perform a functiontest j 3 13o_98 2 Removedefective bulbfrom between the contact springs 96 43 19 Removing and installing bulb for engine compartment light Printed in Germany 8 1998 996969 96 19 www WorkshopManuals co uk ...
Страница 147: ...lon key grip 7 Thefollowingmessage appearson the screen Pleaseconfirm input Checkthe input and pressthe F7 keyto confirmthe input If the key is stolen or the hand held transmitter is faulty all keysstill in the customer s possessionwill be required 8 Distinguishbetweenloss and fault and additionalhand held transmitter for the transponder Note a Teachingan additionalhand held transmitter Duringmain...
Страница 148: ...redfor this purpose Pressthe lockingbutton on the hand held transmitter andthen insert the vehicle keyinto the ignition lock switch on the ignitionand re establishcommunicationwith the control module Current radio key showsthe radio code of the vehicle key that is presently insertedin the ignitionlock Inthis case it is first necessaryto identify and deletethe stored transpondercode of the lost han...
Страница 149: ...osition usingthe arrow keys and v then delete the radio code with key F3 Then pressthe F8 key 13 Carefullyinputthe 24 digit code numberwith the arrow keys A or v and press the double arrow key 14 Thefollowingmessage appearson the screen Pleaseconfirm input Checkthe inputand pressthe F7 key 15 Nowthe hand held transmitter is taught Go back to the menuitem Learning function removethe key and switch ...
Страница 150: ... switch for parking lightand hazardwarning lights remainswitchedon Returning the emergency switch to initial position Press the red emergencyswitchonce more and close the cover External emergency switch The externalemergencyswitch is located under the front lid in the cover abovethe fluid tank The red pull loop of the external emergency switch can be detachedand routed outside alongthe rear edge o...
Страница 151: ...driver Removing key from the bottom part J 1 In order to removethe keyfrom the bottom part the compressionspring in the sliding latch is compressedand heldwith a small screwdriver 3 Insert thecapfromaboveandrelieve the compression spring 4 Pressthe top and bottom parts of the hand held transmittertogetherfirmly 2 Lift outthe cap and relievethe compression spring c 96620001 3 Push the sliding latch...
