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Porsche 996 TT, Руководство по ремонту

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5 Safety notes

Safety instructions for raising vehicles

Safety instructions for welding

Safety instructions for sticking

Safety instructions for installation work

Safety instructions for corrosion protection

top of page

Safety instructions for raising vehicles

Danger of injury when raising vehicles

 DANGER 

Risk of fatal injury due to vehicles slipping or tilting off lifting platforms!

Risk of injury due to vehicles slipping or tilting off lifting platforms may be caused by improper
alignment of the lifting platform arms or mounting plates, and by raising, supporting or removing
units on raised vehicles!

• 

Align the vehicle evenly between the lifting platform columns.

• 

Lift the vehicle only at the take−up points provided.

• 

Check the correct seating 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 must be secured on the lifting platform when removing or supporting units or the shift in the
centre of gravity must be compensated with corresponding loads in the vehicle.

• 

In addition, the guidelines of the lifting platform manufacturers and the legal accident prevention
regulations and those of the mutual indemnity association (VGB 14) must be observed.

• 

Damage when raising vehicles

 CAUTION 

Danger of material damage if the vehicle is raised incorrectly!

Lifting or supporting the vehicle at unsuitable take−up points can lead to material damage on the
vehicle!

• 

Lift the vehicle only at the approved take−up points!

• 

Raising the vehicle in the sill area will lead to the deformation of body parts and to leakage in the
underbody area!

• 

5 Safety notes

183

Содержание 996 TT

Страница 1: ...einordnung...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 808: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tightening torques 745...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 846: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installation 783...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 899: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installation 836...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 906: ...13 Install covers A B 996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installation 843...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 913: ...50 55 19 Removing and installing the wing 50 55 19 Removing and installing the wing 850...

Страница 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...

Страница 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...

Страница 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...

Страница 917: ...50 56 19 Removing and installing wheel housing liners front 50 56 19 Removing and installing wheel housing liners front 854...

Страница 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...

Страница 919: ...53 69 19 Removing and installing wheel housing liners rear 53 69 19 Removing and installing wheel housing liners rear 856...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 925: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung Removing and installing support for cap release 862...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 931: ...55 22 19 Removing and installing front lid 55 22 19 Removing and installing front lid 868...

Страница 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...

Страница 933: ...55 22 37 Disassembling and assembling front lid 55 22 37 Disassembling and assembling front lid 870...

Страница 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...

Страница 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...

Страница 936: ...55 25 19 Removing and installing front lid hinge 55 25 19 Removing and installing front lid hinge 873...

Страница 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...

Страница 938: ...55 37 19 Removing and installing filler flap 55 37 19 Removing and installing filler flap 875...

Страница 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...

Страница 940: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung 55 37 19 Removing and installing filler flap 877...

Страница 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...

Страница 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...

Страница 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...

Страница 944: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung Assembling release for rear lid 881...

Страница 945: ...55 86 19 Removing and installing lower part of lid lock 55 86 19 Removing and installing lower part of lid lock 882...

Страница 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...

Страница 947: ...7 996420 996421 996450 996451 996430 996431 996840 996841 einordnung 55 86 19 Removing and installing lower part of lid lock 884...

Страница 948: ...55 90 19 Removing and installing rear lid 55 90 19 Removing and installing rear lid 885...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 957: ...55 91 19 Removing and installing lid hinge 55 91 19 Removing and installing lid hinge 894...

Страница 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...

Страница 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...

Страница 960: ...57 11 37 Disassembling and assembling door handle 57 11 37 Disassembling and assembling door handle 897...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 997: ...63 15 37 Disassembling and assembling front spoiler Disassembling front spoiler Assembling front spoiler 63 15 37 Disassembling and assembling front spoiler 934...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1003: ...996420 996421 996450 996451 einordnung Installing front spoiler 940...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1022: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung Additional instructions for replacing the rear spoiler 959...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1035: ...996420 996421 996450 996451 996840 996841 einordnung Installing air inlet 972...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1044: ...996420 996421 996450 996451 einordnung Installing rear spoiler 981...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1049: ...996420 996421 996450 996451 996840 996841 996430 996431 einordnung Installing the rearview mirror 986...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1059: ...996420 996421 996450 996451 996840 996841 996430 996431 einordnung Assembling sun visor 996...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1072: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung Installing driver s airbag unit 1009...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1112: ...B 4 2 x 14 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Removing and installing oddments compartment lid 1049...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1145: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing the condenser 1082...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1163: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Installing GPS antenna 1100...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1175: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing wiper link 1112...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1191: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Installation 1128...

Страница 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...

Страница 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...

Страница 1194: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing gas discharge lamp Xenon headlights 1131...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1208: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Installing rear angle sensor for headlight beam adjustment 1145...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1224: ...996420 996421 996450 996451 996620 996621 996650 996651 996840 996841 einordnung Removing and installing passenger compartment monitoringsensor 1161...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1302: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tightening torques 1239...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1310: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tools 1247...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1324: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Tightening torques 1261...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1507: ...57 51 16 Setting the door 57 51 16 Setting the door 1444...

Страница 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...

Страница 1509: ...57 51 19 Removing and installing door 57 51 19 Removing and installing door 1446...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1581: ...996630 996631 996620 996621 996650 996651 einordnung Tightening torques 1518...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1587: ...top of page Removing hydraulic cylinder einordnung Removing hydraulic cylinder 1524...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1612: ...996420 996421 996450 996451 996840 996841 996430 996431 einordnung Installing inner sill 1549...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1627: ...68 17 19 Removing and installing center console front section 68 17 19 Removing and installing center console front section 1564...

Страница 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...

Страница 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...

Страница 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...

Страница 1631: ...68 17 19 Removing and installing center console 68 17 19 Removing and installing center console 1568...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1687: ...70 41 19 Removing and installing floor covering 70 41 19 Removing and installing floor covering 1624...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1739: ...Remove faulty part End 996420 996421 996450 996451 996430 996431 996840 996841 einordnung Test plan for the seat adjustment 1676...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1744: ...996420 996421 996450 996451 996620 996621 996650 996651 einordnung Test plan for the front seat height adjustment 1681...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1754: ...996420 996421 996450 996451 996430 996431 996840 996841 einordnung Test plan for the rear seat height adjustment 1691...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1861: ...996420 996421 996450 996451 996430 996431 996620 996621 996650 996651 996630 996631 einordnung Checking the hardtop 1798...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1937: ...996840 996841 einordnung Tightening torques 1874...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1954: ...Guide tube for release bearing on transmission housing M6x14 10 996840 996841 einordnung Tightening torques 1891...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1974: ...996840 996841 einordnung Tightening torques 1911...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 2023: ...996840 996841 einordnung Removing and installing rear lid 1960...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 2041: ...996840 996841 einordnung Installing front spoiler 1978...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 2046: ...996840 996841 einordnung Replacing rear spoiler fork 1983...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 2077: ...55 90 19 Removing and installing rear lid Carrera 4S 55 90 19 Removing and installing rear lid Carrera 4S 2014...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 2090: ...55 91 19 Removing and installing rear lid hinges Carrera 4S 55 91 19 Removing and installing rear lid hinges Carrera 4S 2027...

Страница 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...

Страница 2092: ...996430 996431 einordnung 55 91 19 Removing and installing rear lid hinges Carrera 4S 2029...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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