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Information on handling of the GT2 scope. ......................................................................................................1 0 Technical data..................................................................................................................................................2 Engine......................................................................................................................................................3 Engine design...........................................................................................................................................4 Engine cooling.........................................................................................................................................5 Engine lubrication....................................................................................................................................5 Engine control..........................................................................................................................................5 Heating.....................................................................................................................................................6 Fuel system..............................................................................................................................................6 Electrical system......................................................................................................................................6 Exhaust system........................................................................................................................................7 Emission control......................................................................................................................................7 Transmission............................................................................................................................................7 Clutch.......................................................................................................................................................7 Transmission............................................................................................................................................8 Body designs............................................................................................................................................9 Running gear............................................................................................................................................9 Brakes....................................................................................................................................................10 Wheels and tyres....................................................................................................................................11 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 Lifting the vehicle..................................................................................................................................16 Power unit..........................................................................................................................................................17 Engine M96/70......................................................................................................................................17 Engine....................................................................................................................................................18 Engine design.........................................................................................................................................18 Engine cooling.......................................................................................................................................19 Engine lubrication..................................................................................................................................19 Engine control........................................................................................................................................20 0 Transmission..................................................................................................................................................21 6speed manual transmission G 96.50..................................................................................................21 Front wheel drive Z 96.00 ......................................................................................................................22 0 Body .................................................................................................................................................................23 Body of highstrength steel 1................................................................................................................23 Body of highstrength steel 2................................................................................................................24 Water drainage plan 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0 Body Refrigerant circuit..................................................................................................................................26 Component arrangement, Airbag System B05......................................................................................26 0 Electrics...........................................................................................................................................................28 Fuse assignments...................................................................................................................................28 0 Power supply..................................................................................................................................................31 Work instructions after disconnecting the battery.................................................................................31 Control module memories.....................................................................................................................31 Supply voltage fault entry......................................................................................................................32 Test drive after connecting the battery ...................................................................................................32 2470 DME control module....................................................................................................................32 3730 Tiptronic ........................................................................................................................................33 6452 Power windows.............................................................................................................................33 90 25 Instrument cluster .........................................................................................................................33 9030 Clock.............................................................................................................................................33 9023 Fuel level display..........................................................................................................................34 9120 Radio.............................................................................................................................................34 9110 PCM..............................................................................................................................................34 01 General maintenance: Test drive...............................................................................................................36 01 Diagnostic system: Read out fault memory and activate systems...........................................................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, headlight washer...............................................................................40 Mix ratio of fluids for windscreen washer system.................................................................................40 01 Checking the function of the vehicle's lights and the headlight setting..................................................41 Checking the adjustment of the headlights............................................................................................41 Adjusting the main headlights...............................................................................................................42 Adjusting the main headlights, USA version .........................................................................................43 Fog light adjustment..............................................................................................................................43 01 Checking the function of electrical equipment, as well as the indicator and warning lights................45 01 Alarm system: checking operation of indicators .......................................................................................46 01 Activating/deactivating the parking aid .....................................................................................................47 General...................................................................................................................................................47 Activating the parking aid without PST 2.............................................................................................47 ii

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01 Activating/deactivating the parking aid Deactivating the parking aid without PST 2..........................................................................................48 Activating the parking aid with PST 2 ...................................................................................................48 Selecting door mirror to be lowered, left/right......................................................................................49 Adjusting the lowering angle for the passenger door mirror.................................................................49 Deactivating the parking aid with PST 2...............................................................................................50 01 Removing transport lock (spring strut locking devices) Turbo and GT2...........................................51 General...................................................................................................................................................51 Removing spring strut locking devices..................................................................................................51 Technical Data GT2 .......................................................................................................................................53 Engine....................................................................................................................................................54 Engine design.........................................................................................................................................54 Engine cooling.......................................................................................................................................55 Engine lubrication..................................................................................................................................55 Engine control........................................................................................................................................55 Fuel system............................................................................................................................................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....................................................................................................................................60 Exhaust system......................................................................................................................................60 Emission control....................................................................................................................................60 Precautionary measures when working on fuel system .................................................................................61 03 Diagnostic system: reading out fault memory...........................................................................................62 Reading out fault memory.....................................................................................................................62 03 General maintenance: test drive.................................................................................................................63 03 Removing and installing drive belt .............................................................................................................64 Removal overview of the drive belt (engine installed)..........................................................................64 Installation overview of the drive belt (engine installed)......................................................................65 94 56 19 Removing and installing bulb for direction indicator light...........................................................67 Removing bulb for direction indicator light..........................................................................................67 Installing bulb for direction indicator light............................................................................................67

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03 Changing the engine oil and oil filter.........................................................................................................68 03 Changing the engine oil (without oil filter)................................................................................................72 03 Replacing spark plugs ..................................................................................................................................74 Removing spark plugs...........................................................................................................................74 Installing spark plugs.............................................................................................................................75 03 Checking cooling system ..............................................................................................................................77 Coolant: checking level, antifreeze content and leaks...........................................................................77 03 Replacing air cleaner element.....................................................................................................................79 Removing air cleaner.............................................................................................................................79 Installing air cleaner ...............................................................................................................................81 03 Replacing the fuel filter...............................................................................................................................85 03 Clutch: checking the play and pedal end position....................................................................................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 topping up the ATF.............................................................................................................91 Tools......................................................................................................................................................91 Checking and topping up the ATF.........................................................................................................91 Tightening torques.................................................................................................................................93 03 Replacing ATF.............................................................................................................................................94 Tools......................................................................................................................................................94 Replacing ATF fluid..............................................................................................................................94 Tightening torques.................................................................................................................................96 03 Removing and installing ATF filter ............................................................................................................97 Tools......................................................................................................................................................97 Removing ATF filter.............................................................................................................................97 Installing ATF filter...............................................................................................................................98 Tightening torques.................................................................................................................................99 03 Replacing and checking transmission oil in final drive..........................................................................100 Tools....................................................................................................................................................100 Changing transmission oil in final drive..............................................................................................100 Tightening torques...............................................................................................................................102

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03 Changing transmission oil in front wheel drive......................................................................................103 Changing transmission oil in front wheel drive...................................................................................103 Tightening torques...............................................................................................................................103 03 Changing transmission oil GT2.............................................................................................................105 Changing transmission oil GT2........................................................................................................105 Topping up transmission oil GT2.....................................................................................................105 Tightening torques...............................................................................................................................106 03 Steering gear: fluid level and bellows .......................................................................................................107 Power steering: checking the fluid level..............................................................................................107 General..........................................................................................................................................107 Power steering: checking the fluid level.......................................................................................107 Steering gear: visual inspection of the bellows ....................................................................................109 03 Axle joints/drive shafts..............................................................................................................................110 Tie rod ends: checking the play and dust bellows...............................................................................110 Axle joints: checking the play and dust bellows ..................................................................................110 Drive shafts: visual inspection of the boots.........................................................................................111 03 Running gear adjustment/storage of assemblies.....................................................................................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 pressure for cold tyres (approx. 20 C).......................................................................................113 911 Turbo......................................................................................................................................113 911 GT2 (M002/M003).................................................................................................................113 03 Checking and changing the brake fluid...................................................................................................115 Checking the brake fluid level.............................................................................................................115 Changing the brake fluid ......................................................................................................................115 03 Parking brake: checking the free play of the parking brake lever.......................................................117 Parking brake: checking the free play of the parking brake lever.......................................................117 Adjusting the parking brake..........................................................................................................117 03 Visual inspection: brake lines/brake pads/brake discs...........................................................................119 Brake hoses and lines...........................................................................................................................119 Brake system: visual inspection of the brake pads and brake discs for wear......................................119 03 Checking the wheel mounting...................................................................................................................121 03 Checking lid and doors..............................................................................................................................122 Checking lid lock, front and rear.........................................................................................................122 Checking the catch bar..................................................................................................................122 Checking safety hook, front lid ............................................................................................................122 v

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03 Checking lid and doors Function test, checking door lock........................................................................................................122 Functional inspection of the tank cap lock..........................................................................................123 Checking door and lid tightening torques............................................................................................123 Checking inner release of luggage compartment (Trunk Entrapment) ................................................123 Tightening torques...............................................................................................................................124 03 Checking seat belts.....................................................................................................................................125 Functional inspection...........................................................................................................................125 Condition inspection............................................................................................................................125 03 Inspecting the airbag system.....................................................................................................................126 Visual inspection ..................................................................................................................................126 Checking airbag warning light.............................................................................................................126 Function test of the airbag system.......................................................................................................126 03 Passenger protection maintenance: checking rollover protection system..........................................128 03 Particle filter: replacing the filter element..............................................................................................129 Removing particle filter.......................................................................................................................129 Installing particle filter .........................................................................................................................129 03 Checking the function of the vehicle's 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 wiper/washer system, headlight washer.............................................................................135 03 Checking the function of electrical equipment, as well as the indicator and warning lights..............136 03 Additional maintenance USA................................................................................................................137 Additional maintenance, replacing spark plugs...................................................................................137 Additional maintenance every 60,000 mls/96,000 km........................................................................137 Additional maintenance every 90,000 mls/144,000 km......................................................................138 Maintenance every 2 years ...................................................................................................................138 Maintenance after 4, 8, 10 then every 2 years.....................................................................................138 03 Additional maintenance as of MY 2004................................................................................................139 Additional maintenance, replacing spark plugs...................................................................................139 Additional maintenance every 80,000 km/48,000 mls........................................................................139 Additional maintenance every 160,000 km/96,000 mls......................................................................139 Maintenance every 2 years ...................................................................................................................140 Maintenance after 4, 8, 10 then every 2 years.....................................................................................140

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03 Additional maintenance USA as of MY 2004...................................................................................141 Additional maintenance, replacing spark plugs...................................................................................141 Additional maintenance every 60,000 mls/96,000 km........................................................................141 Additional maintenance every 90,000 mls/144,000 km......................................................................142 Maintenance every 2 years ...................................................................................................................142 Maintenance after 4, 8, 10 then every 2 years.....................................................................................142 03 Additional maintenance .............................................................................................................................144 Additional maintenance, replacing spark plugs...................................................................................144 Additional maintenance every 80,000 km/48,000 mls........................................................................144 Additional maintenance every 160,000 km/96,000 mls......................................................................144 Maintenance every 2 years ...................................................................................................................145 Maintenance after 4, 8, 10 then every 2 years.....................................................................................145 3 Technical data..............................................................................................................................................146 6speed manual transmission G 96.50................................................................................................146 Manual transmission tightening torques ........................................................................................147 Front wheel drive Z 96.00 ....................................................................................................................147 Frontaxle drive tightening torques..............................................................................................148 3 Technical data..............................................................................................................................................149 5speed Tiptronic transmission A 96.50150.....................................................................................149 Tightening torques for Tiptronic transmission..............................................................................150 Front wheel drive Z 96.00 ....................................................................................................................151 Frontaxle drive tightening torques..............................................................................................151 4 Removing transport lock (spring strut locking devices) Turbo and GT2...........................................153 General.................................................................................................................................................153 Removing spring strut locking devices................................................................................................153 4 Lifting the vehicle.........................................................................................................................................155 Lift the vehicle.....................................................................................................................................155 4 Tests/notes for allwheel drive...................................................................................................................156 Balancing wheels on vehicle ................................................................................................................156 Power test.............................................................................................................................................156 Brake test.............................................................................................................................................156 Towing manual transmission vehicles.................................................................................................156 Towing Tiptronic vehicles...................................................................................................................156 4 Switching off PSM ........................................................................................................................................157 Switching off PSM ...............................................................................................................................157 Switching PSM back on.......................................................................................................................157 Characteristic features of Tiptronic vehicles (slip upshift)..................................................................158 5 Plug location plan .........................................................................................................................................159 Top of front end...................................................................................................................................159 Bottom of front end ..............................................................................................................................160 vii

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5 Plug location plan Side of front end ...................................................................................................................................160 Bottom of lower side member and floor..............................................................................................161 Top of lower side member and floor ....................................................................................................161 Bottom of rear end...............................................................................................................................162 Top of rear end.....................................................................................................................................162 Side of rear end....................................................................................................................................163 Seam seals........................................................................................................................................................164 Accessories..........................................................................................................................................164 Front lid.........................................................................................................................................165 Door...............................................................................................................................................165 Sliding roof panel..........................................................................................................................166 5 Work sequence for accident repair............................................................................................................167 5 Work sequence for determining scope of damaged vehicles involved in an accident...........................169 5 Corrosion protection measures during repairs.........................................................................................171 Measures for maintaining longterm body protection........................................................................171 Prerequisite for ensuring vailidity of the longlife guarantee.............................................................171 5 Vehicle identification number.....................................................................................................................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 of lower side member and floor...............................................................177 Overview diagram, lower rear end .......................................................................................................178 Tools and materials..............................................................................................................................178 5 Water drainage plan Cabriolet...............................................................................................................179

5 Check dimensions for body repair Cabriolet structure........................................................................180 Structure dimensions for cabriolet.......................................................................................................180 5 Safety notes...................................................................................................................................................183 Safety instructions for raising vehicles................................................................................................183 Danger of injury when raising vehicles .........................................................................................183 Damage when raising vehicles......................................................................................................183 Safety instructions for welding............................................................................................................184 Dangers of injury when welding...................................................................................................184 Safety instructions for flying sparks during grinding and welding work......................................184 Safety instructions for fuel tank....................................................................................................185 Safety instructions for air conditioning.........................................................................................185 viii

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5 Safety notes Safety instructions for sticking............................................................................................................185 Safety instructions for Teromix6700 twocomponent adhesive................................................185 Safety instructions for installation work..............................................................................................186 Safety instructions for sharpedged body and unit parts..............................................................186 Safety instructions for airbag system............................................................................................186 Safety instructions for door...........................................................................................................186 Safety instructions for corrosion protection .........................................................................................187 Safety instructions for plug location plan (body)..........................................................................187 Safety instructions for water drains (body)...................................................................................187 5 General information and quality notes......................................................................................................188 Measures for maintaining longterm body protection........................................................................188 Prerequisite for maintaining the longlife guarantee....................................................................188 Electronic control modules..................................................................................................................188 Protection against 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 Compressedair equipment...........................................................................................................191 Welding equipment.......................................................................................................................192 5 Diagram keys to symbols for welding work...........................................................................................193 Resistance spot welding.......................................................................................................................193 Inertgas arc welding (MAG procedure) .............................................................................................193 Gas welding.........................................................................................................................................193 5 Check dimensions for body repair.............................................................................................................195 Floorpan check dimensions ..................................................................................................................195 5 Water drainage plan....................................................................................................................................198 5 Diagram body gap dimensions................................................................................................................199 Gap dimensions, body front.................................................................................................................199 Gap dimensions, body centre...............................................................................................................201 Gap dimensions, body rear..................................................................................................................202 Gap dimensions, body rear Carrera 4S.............................................................................................204 Diagram Gap dimensions, Cabriolet................................................................................................206 Diagram Centre gap dimensions, Cabriolet...............................................................................206 Diagram Gap dimensions, rear Cabriolet...................................................................................208 Diagram, gap dimensions, Cabriolet rear Carrera 4S................................................................209 Diagram Gap dimensions, hardtop .............................................................................................210

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5 Body parts of highstrength steel...............................................................................................................212 Highstrength steel plates ....................................................................................................................213 Tailored blanks .....................................................................................................................................214 Baked hardening..................................................................................................................................215 Straightening body parts......................................................................................................................215 Welding work .......................................................................................................................................216 Reshaping .............................................................................................................................................216 Separation points ..................................................................................................................................216 Diagram Body, model year 2002 ......................................................................................................217 Structural body parts (model care) for model year 2002 ...............................................................217 6 Safety notes...................................................................................................................................................219 Safety instructions for work on car windows......................................................................................219 Danger of injury when working on car windows..........................................................................219 Material damage when removing the glass from car windows.....................................................219 Material damage when inserting the glass into car windows........................................................219 Safety instructions for installation work..............................................................................................220 Safety instructions for airbag system............................................................................................220 Safety instructions for sliding roof................................................................................................220 Safety instructions for rear spoiler................................................................................................220 Safety instructions for the pump unit hydraulic system 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 6 Overview of exterior colours.......................................................................................................................231 Exterior paintwork solid...................................................................................................................231 Exterior paintwork metallic/pearl.....................................................................................................231 Special colours.....................................................................................................................................232 6 Processing of Porsche 2component window bonding agents.................................................................234 Overview of tools and materials..........................................................................................................234 Preparing the adhesive surfaces...........................................................................................................235 Combined procedure (handling double cartridge press)......................................................................236 7 Special notes for the care of softlook paint surfaces ...............................................................................239 Light soiling (e.g. dust)........................................................................................................................239 Heavy soiling (e.g. oily, greasy dirt) ....................................................................................................239 8 Air conditioning...........................................................................................................................................241 Technical data for the airconditioning system...................................................................................241 9 Work instructions after disconnecting the battery...................................................................................242 Effect of disconnection or total discharge of the battery on electrical systems in the vehicle, subsequent measures...........................................................................................................................242 Control module memories...................................................................................................................242 Supply voltage fault entry....................................................................................................................243 x

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9 Work instructions after disconnecting the battery Test drive after connecting the battery .................................................................................................243 2470 DME control module..................................................................................................................243 6452 Power windows...........................................................................................................................244 90 25 Instrument cluster .......................................................................................................................244 9030 Clock...........................................................................................................................................244 9023 Fuel level display........................................................................................................................244 9120 Radio...........................................................................................................................................245 9110 PCM............................................................................................................................................245 30 Clutch: checking fluid levels.....................................................................................................................247 General.................................................................................................................................................247 Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment and luggage compartment.......................................................................................................................................247 Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment..........................................248 Checking Pentosin CHF 11 S hydraulic fluid in the luggage compartment........................................249 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 Frontaxle final drive/drive shaft (Turbo)...........................................................................................252 Stabilizer..............................................................................................................................................253 Steering................................................................................................................................................253 Wheel fastening...................................................................................................................................253 42 Tightening torques for rear axle...............................................................................................................255 Carrier side section/cross member.......................................................................................................255 Axle strut ..............................................................................................................................................255 Wheel carrier ........................................................................................................................................256 Spring strut...........................................................................................................................................256 Drive shaft/stabilizer............................................................................................................................257 Unit mount...........................................................................................................................................257 44 Conversion table for wheel alignment values..........................................................................................258 Minutes in decimal degrees.................................................................................................................258 Conversion from minutes to decimal degrees (examples)............................................................258 Conversion from decimal degrees to minutes (examples)............................................................258 44 Adjusting values for suspension alignment Turbo and GT2..............................................................260 Vehicle height......................................................................................................................................260 Wheel alignment values.......................................................................................................................260 44 Alignment card Turbo ............................................................................................................................262

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44 Suspension alignment, complete...............................................................................................................264 Vehicle height/wheel load ....................................................................................................................265 Wheelalignment corrections..............................................................................................................265 Rear axle........................................................................................................................................265 Front axle .......................................................................................................................................266 General procedure for suspension alignment .......................................................................................266 Vehicle height (vehicle height check) ..................................................................................................267 General..........................................................................................................................................267 Preliminary work...........................................................................................................................267 Front axle .......................................................................................................................................268 Rear axle........................................................................................................................................268 Wheel alignment ............................................................................................................................268 Rear axle..............................................................................................................................................269 Adjusting camber..........................................................................................................................269 Adjusting toe.................................................................................................................................270 Front axle.............................................................................................................................................271 Adjusting camber..........................................................................................................................271 Adjusting caster.............................................................................................................................271 Adjusting toe.................................................................................................................................272 Toedifference 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 tires and wheels (series)..................................................................................................276 Notes on mounting tires................................................................................................................276 44 Tyres............................................................................................................................................................277 Mounting instructions..........................................................................................................................277 General..........................................................................................................................................277 Uncontrolled matching..................................................................................................................278 Controlled matching......................................................................................................................278 Fitting............................................................................................................................................278 Balancing weights................................................................................................................................279 Navigation system ................................................................................................................................279 Wheel storage .......................................................................................................................................279 Tyre age...............................................................................................................................................280 44 Checking disc wheels.................................................................................................................................281 Checking the radial and lateral runout.................................................................................................281 44 Tyre mounting............................................................................................................................................282 Tools....................................................................................................................................................282 Notes on removing/mounting tyres ......................................................................................................283 Removal...............................................................................................................................................283 Fitting...................................................................................................................................................284 xii

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44 Balancing/optimising wheels.....................................................................................................................287 General.................................................................................................................................................287 Balancing/optimising wheels...............................................................................................................287 Further to 1: Mounting the tyre on the rim ....................................................................................288 Further to 2: Stationary balancing with optimisation of the rolling smoothness..........................288 Further to 3: Mounting the wheel on the vehicle..........................................................................289 Further to 4: Electronic fine balancing..........................................................................................289 Further to 4a: Fine balancing of the front wheels.........................................................................290 Further to 4b: Fine balancing of the rear wheels...........................................................................290 Balancing weights................................................................................................................................291 Affixing the adhesive weights.......................................................................................................291 45 ABS/PSM 5.7 check with Porsche System Tester 2................................................................................292 Test with Porsche System Tester 2......................................................................................................292 46 Checking brake light switch setting.........................................................................................................293 Brake light switch setting....................................................................................................................293 Checking brake light switch setting.....................................................................................................293 Adjusting switch if pedal travel is too small ........................................................................................294 1st possibility: ................................................................................................................................294 2nd 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 discs..............................................................................296 Wear limit technical data Turbo with cast iron brake discs.............................................................297 46 Checking the thickness of the disc brake pads Turbo and GT2 .........................................................298 46 Technical data/Brake wear limit Turbo with PCCB...........................................................................300 Technical data Turbo with ceramic brake discs (PCCB).................................................................300 Wear limit technical data Turbo with ceramic brake discs (PCCB) .................................................301 47 Tightening torques for brake hydraulics.................................................................................................302 48 Tightening torques for steering................................................................................................................303 48 Test and assembly work on power steering.............................................................................................304 General.................................................................................................................................................304 Checking hydraulic fluid of power steering and servo clutch.............................................................304 Bleeding the steering system...............................................................................................................305 48 Assessment of steering gear after accident damage................................................................................307 Fundamentals.......................................................................................................................................307 Assessment of the steering of a vehicle involved in an accident..................................................307 Exceptional regulation / order handling........................................................................................308 xiii

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69 Safety regulations for vehicles with airbag and belt tensioner..............................................................309 Assembly and adjustment work...........................................................................................................310 Handling airbag and belt tensioner......................................................................................................311 Dangers for persons and the environment.....................................................................................311 Protective measures and rules of behaviour..................................................................................311 Behaviour in cases of malfunction or danger................................................................................312 Materials........................................................................................................................................313 General information.............................................................................................................................313 Component exchange after airbag triggering................................................................................314 After triggering of the side airbag unit..........................................................................................314 After triggering of belt tensioner...................................................................................................314 87 Nominal values for pressures and temperatures .....................................................................................315 General test prerequisites.....................................................................................................................315 Centre vent temperature as a function of ambient temperature .....................................................315 High pressure in cold circuit as a function of ambient temperature ..............................................316 Low pressure in cold circuit 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 closedcircuit current...................................................................................................321 Tools....................................................................................................................................................321 Preparations on the vehicle..................................................................................................................321 Connecting measuring device.......................................................................................................321 Measurement........................................................................................................................................322 27 06 Battery....................................................................................................................................................324 Battery handling notes......................................................................................................................324 Warning notes and safety regulations for hydrocyanic acid batteries...........................................325 Removing and installing battery..........................................................................................................325 Remove battery....................................................................................................................................326 Install battery.......................................................................................................................................327 Visual inspection ..................................................................................................................................328 Check acid level...................................................................................................................................328 Checking gravity of electrolyte ............................................................................................................329 Opencircuit voltage measurement.....................................................................................................330 Battery load test...................................................................................................................................331 Charging battery ...................................................................................................................................332 27 06 Electrical emergency release, front cover...........................................................................................334 Emergency release, front cover ............................................................................................................334 40 09 Frontaxle cross member permissible combinations.....................................................................336 New frontaxle cross member as of model '02................................................................................336 Allocating the frontaxle cross member to the body...........................................................................336 xiv

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40 09 Frontaxle cross member permissible combinations Impermissible combination...........................................................................................................337 Permissible combinations..............................................................................................................337 Impermissible combination...........................................................................................................338 40 Disassembling and assembling front spring strut...................................................................................339 Tools....................................................................................................................................................339 Disassembly and assembly instructions...............................................................................................341 Disassembly ...................................................................................................................................341 Distinguishing feature of coil springs and dampers......................................................................342 Preliminary work and notes on assembly......................................................................................342 Assembly.......................................................................................................................................343 42 71 Disassembling and assembling rear spring strut Turbo................................................................346 Tools....................................................................................................................................................346 Disassembling and assembling rear spring strut..................................................................................346 Disassembly and assembly instructions...............................................................................................348 Disassembly ...................................................................................................................................348 Distinguishing feature of coil springs and dampers......................................................................350 Assembly.......................................................................................................................................350 44 27 Instructions 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 Steering angle sensor............................................................................................................................355 Calibrating steering angle sensor.........................................................................................................355 Steering angle sensor position.......................................................................................................355 The steering angle sensor must be calibrated after:......................................................................355 Calibrating steering angle sensor..................................................................................................356 Check the steering angle sensor actual value in the following cases:...........................................357 Checking the steering angle sensor actual value...........................................................................357 66 72 Assignment of spoiler drive, relays and instrument cluster..............................................................358 Variants of the spoiler drive .................................................................................................................358 69 59 Disposal of airbag and belt tensioner units .........................................................................................359 Safety measures when igniting airbag units .........................................................................................359 Tools....................................................................................................................................................360 Connecting ignition tool......................................................................................................................361 Driver's side...................................................................................................................................361 Passenger's side.............................................................................................................................361 Side airbag.....................................................................................................................................361 Belt tensioner .................................................................................................................................362 Ignition.................................................................................................................................................362

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87 03 Safety regulations when handling refrigerant R134a........................................................................364 92 66 Nonadjustable spray nozzles ..............................................................................................................365 94 23 Bulb table and installation instructions..............................................................................................366 Bulb table.............................................................................................................................................366 Installing bulbs.....................................................................................................................................366 96 22 Bulb table and installation instructions..............................................................................................367 Bulb table.............................................................................................................................................367 Installing bulbs.....................................................................................................................................367 97 68 Optical waveguide MOST bus..........................................................................................................368 Specifications on handling the optical waveguide...............................................................................368 Storage, packaging, transport........................................................................................................368 Installing optical waveguides in the vehicle ..................................................................................368 Repairs...........................................................................................................................................369 Plug connectors....................................................................................................................................369 Protective dust caps.......................................................................................................................369 Control module plug connector (wiring harness side)..................................................................370 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 Installing optical contacts on bushing side....................................................................................374 Optical waveguide modules.................................................................................................................375 Tools....................................................................................................................................................376 01 Sales check..................................................................................................................................................377 03 24 00 Minor maintenance..........................................................................................................................379 03 26 00 Major maintenance..........................................................................................................................381 03 50 00 Annual maintenance........................................................................................................................383 10 01 00 Tightening torques for M 96/70 engine..........................................................................................385 Crankshaft/crankcase...........................................................................................................................385 Cylinder, cylinder head and camshaft housing....................................................................................385 10 10 37 Disassembling and assembling crankcase ......................................................................................387 Tools....................................................................................................................................................387 Adapting engine holder........................................................................................................................390 Left crankcase half (cylinder bank 1 3)............................................................................................392 Right crankcase half (cylinder bank 4 6)..........................................................................................394 Disassembling the crankcase...............................................................................................................396 Assembling the crankcase....................................................................................................................399 xvi

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13 10 19 Removing and installing pistons (includes removing and installing cylinders).........................411 Tools....................................................................................................................................................411 Removing pistons and cylinders..........................................................................................................412 Removing pistons................................................................................................................................414 Installing pistons and cylinders ............................................................................................................415 13 19 21 Removing piston rings.....................................................................................................................423 Tools....................................................................................................................................................423 Removal...............................................................................................................................................423 13 19 23 Installing piston rings......................................................................................................................427 Tools....................................................................................................................................................427 Installation...........................................................................................................................................427 13 48 37 Disassembling and assembling crankshaft....................................................................................431 Tools....................................................................................................................................................431 Disassembling crankshaft....................................................................................................................433 Identifying the ring knurled screw................................................................................................434 Pressing ring knurled screw in and out................................................................................................435 Pressing ring knurled screw out....................................................................................................435 Pressing 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 Removal overview of the drive belt (engine installed)........................................................................443 Remove drive belt................................................................................................................................444 Installation overview of the drive belt (engine installed)....................................................................446 Install drive belt...................................................................................................................................448 15 03 21 Removing camshaft housing engine removed............................................................................450 Tools....................................................................................................................................................450 Component overview and tightening torques......................................................................................450 Removing the camshaft housing..........................................................................................................453 15 03 23 Installing camshaft housing............................................................................................................458 15 05 02 Checking camshafts (timing) engine removed...........................................................................460 Tools....................................................................................................................................................460 Checking camshafts.............................................................................................................................461 15 05 16 Setting camshafts (timing) engine removed...............................................................................467 Tools....................................................................................................................................................467 Setting the camshafts (timing).............................................................................................................468

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15 05 19 Removing and installing camshafts engine removed .................................................................474 Tools....................................................................................................................................................474 Component overview and tightening torques......................................................................................475 Removing camshafts............................................................................................................................477 Installing camshafts.............................................................................................................................481 15 20 37 Disassembling and assembling intermediate shaft ........................................................................487 15 55 19 Removing and installing hydraulic valve .......................................................................................489 Removing the hydraulic valve.............................................................................................................489 Installing the hydraulic valve...............................................................................................................491 15 70 21 Removing cylinder head..................................................................................................................494 Removing cylinder head......................................................................................................................496 15 70 23 Installing cylinder head...................................................................................................................497 17 04 19 Removing and installing 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 installed..............................................................505 Removal...............................................................................................................................................506 Installation...........................................................................................................................................508 17 40 19 Removing and installing oil cooler Engine removed.................................................................510 Removing oil cooler .............................................................................................................................510 Installing oil cooler..............................................................................................................................511 17 52 19 Removing and installing oil container ............................................................................................514 Removing oil container removal overview......................................................................................514 Installing oil container.........................................................................................................................517 19 38 17 Draining and filling in coolant........................................................................................................520 Draining coolant ...................................................................................................................................521 Filling in coolant..................................................................................................................................521 Bleeding the cooling system................................................................................................................521 19 40 19 Removing and installing coolant expansion tank ..........................................................................523 Removal...............................................................................................................................................523 Installation...........................................................................................................................................527

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19 50 19 Removing and installing coolant pump (engine installed)...........................................................529 Tools....................................................................................................................................................529 Removal...............................................................................................................................................529 Installation...........................................................................................................................................534 19 62 19 Removing and installing coolant hose at front left (Ytype coolant distributor)......................538 Tools....................................................................................................................................................538 Removal...............................................................................................................................................538 Installation...........................................................................................................................................540 20 02 01 Checking fuel pressure....................................................................................................................543 20 10 19 Removing and installing fuel tank..................................................................................................546 Removing fuel tank..............................................................................................................................548 Installing fuel tank...............................................................................................................................553 Tightening torques for front axle and fuel tank .............................................................................557 20 15 01 Calibrating fuel level sensor system...............................................................................................559 20 39 19 Removing and installing fuel return line.......................................................................................560 Removal...............................................................................................................................................560 Installation...........................................................................................................................................561 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 cooler............................................................................................................................572 21 10 19 Removing and installing air guide for charge air cooling............................................................573 Removing air guide for charge air cooling..........................................................................................573 Installing air guide for charge air cooling............................................................................................575 21 30 19 Removing and installing turbocharger..........................................................................................577 Removing turbocharger.......................................................................................................................577 Installing turbocharger.........................................................................................................................579 21 43 19 Removing and installing the charge air cooler..............................................................................583 Removing the charge air cooler...........................................................................................................583 Installing the charge air cooler .............................................................................................................584 21 67 05 Checking and adjusting the bypass flap control boxes on the turbocharger.............................585 Check and adjust (cylinder bank 1 3)...............................................................................................585 Test................................................................................................................................................585 Adjusting.......................................................................................................................................586 xix

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21 67 05 Checking and adjusting the bypass flap control boxes on the turbocharger Check and adjust (cylinder bank 4 6)...............................................................................................586 21 67 19 Removing and installing bypass flap control box on the turbocharger Engine installed......588 Removing bypass flap control box on the turbocharger......................................................................588 Installing bypass flap control box on the turbocharger ........................................................................589 21 75 20 Removing and installing oil container for exhaust turbocharger Engine installed................591 Removing oil container for exhaust turbocharger...............................................................................591 Installing oil container for exhaust turbocharger.................................................................................593 21 80 19 Removing and installing oil pump for turbocharger....................................................................595 Tools....................................................................................................................................................595 Removal...............................................................................................................................................595 Installation...........................................................................................................................................604 21 90 19 Removing and installing pressure sensor......................................................................................609 Removal...............................................................................................................................................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 installing throttle body Engine installed...........................................................617 Removing throttle body.......................................................................................................................617 Installing throttle body.........................................................................................................................618 24 46 01 Testing the intake distributor (leak test).......................................................................................620 Tools....................................................................................................................................................620 Leak test...............................................................................................................................................620 24 46 20 Removing and installing intake distributor Engine removed..................................................622 Removing intake distributor................................................................................................................622 Installing intake distributor..................................................................................................................624 24 46 37 Disassembling and assembling intake distributor........................................................................627 Disassembling the intake distributor ....................................................................................................627 Vacuum lines.......................................................................................................................................629 24 69 19 Precautionary measures when handling oxygen sensors.............................................................631 24 73 19 Removing and installing oxygen sensors behind catalytic converter..........................................632 Removing oxygen sensors behind the catalytic converter...................................................................632 Oxygen sensor, left side :..............................................................................................................633 Oxygen sensor, right side :............................................................................................................633 xx

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24 73 19 Removing and installing oxygen sensors behind catalytic converter Installing oxygen sensors behind the catalytic converter....................................................................634 26 01 05 Exhaust system leak test..................................................................................................................635 Tools....................................................................................................................................................635 Leak test...............................................................................................................................................636 26 33 19 Removing and installing rear mufflers..........................................................................................637 Removing rear mufflers.......................................................................................................................637 Installing rear mufflers .........................................................................................................................639 26 65 19 Removing and installing secondary air pump...............................................................................641 Removal...............................................................................................................................................641 Installation...........................................................................................................................................642 27 22 19 Removing and installing threephase generator..........................................................................643 Removing the threephase generator..................................................................................................643 Installing the threephase generator....................................................................................................644 Undoing and tightening the belt pulley ................................................................................................644 Tool for holding the freewheel pulley...............................................................................................644 27 27 19 Removing and installing bracket for 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 the starter ..............................................................................................................................652 28 39 19 Removing and installing hall sender Engine installed ...............................................................653 Removing hall sender..........................................................................................................................653 Installing hall sender............................................................................................................................654 Tightening torques...............................................................................................................................655 28 70 55 Replacing the spark plugs...............................................................................................................656 Removing spark plugs.........................................................................................................................656 Installing spark plugs...........................................................................................................................657 28 72 20 Removing and installing knock sensor Engine removed..........................................................659 Removing and installing knock sensor, cylinder bank 13.................................................................659 Removing knock sensor, cylinder bank 4 6 ......................................................................................660 Installing knock sensor, cylinder bank 4 6.......................................................................................661 30 01 01 Checking clutch booster circuit......................................................................................................663 1. Checking accumulator.....................................................................................................................663 2. Checking valve (pressureregulating valve)...................................................................................663 2.1 Checking the valve (pressureregulating valve) in the clutch save cylinder..........................664 xxi

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30 01 01 Checking clutch booster circuit 2.2 Checking the valve (pressureregulating valve) in the upper part of the expansion tank......664 30 01 07 Bleeding clutch operation................................................................................................................666 Disposal of Pentosin............................................................................................................................667 30 27 19 Removing and installing clutch pressure hose Engine installed ...............................................668 Removing clutch pressure hose...........................................................................................................668 Installing clutch pressure hose.............................................................................................................669 30 30 19 Removing and installing clutch slave cylinder..............................................................................671 Removal...............................................................................................................................................671 Tightening torques...............................................................................................................................673 Installation...........................................................................................................................................674 30 31 19 Removing and installing the accumulator.....................................................................................676 Removal...............................................................................................................................................676 Installation...........................................................................................................................................677 30 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 Installing clutch ....................................................................................................................................683 Tightening torques...............................................................................................................................683 30 50 37 Disassembling and assembling clutch............................................................................................684 30 56 01 Checking clutch drive plate for wear.............................................................................................685 03 24 00 Minor maintenance USA ..............................................................................................................686 03 24 00 Minor maintenance as of MY 2003.............................................................................................688 03 24 00 Minor maintenance USA as of MY 2003.................................................................................690 03 24 00 Minor maintenance as of MY 2004.............................................................................................692 03 24 00 Minor maintenance USA as of MY 2004.................................................................................694 32 47 19 Removing and installing torqueconverter sealing ring..............................................................696 Tools....................................................................................................................................................696 Removing the torqueconverter sealing ring .......................................................................................696 Installing the torqueconverter sealing ring........................................................................................697

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32 50 19 Removing and installing torque converter....................................................................................698 Tools....................................................................................................................................................698 Removing the torque converter ............................................................................................................698 Installing the torque converter.............................................................................................................699 03 26 00 Major maintenance USA ..............................................................................................................700 03 26 00 Major maintenance as of MY 2003.............................................................................................702 03 26 00 Major maintenance USA as of MY 2003.................................................................................704 03 26 00 Major maintenance as of MY 2004.............................................................................................706 03 26 00 Major maintenance USA as of MY 2004.................................................................................708 34 01 55 Changing transmission oil...............................................................................................................710 Changing transmission oil...................................................................................................................710 Tightening torques...............................................................................................................................710 34 08 19 Removing and installing shift console............................................................................................711 Tools....................................................................................................................................................711 Removing and installing shift console.................................................................................................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 selector cables...............................................................................715 Removing shift and selector cables...............................................................................................716 Installing shift and selector cables .................................................................................................718 Tightening torques...............................................................................................................................719 34 35 27 Removing and refitting the transmission.......................................................................................720 Tools....................................................................................................................................................720 Removing transmission ........................................................................................................................720 Refitting transmission..........................................................................................................................722 Tightening torques...............................................................................................................................723 34 49 19 Removing and installing closure cap for selector force mechanism ............................................724 Tools....................................................................................................................................................724 Removing and installing closure cap for selector force mechanism ....................................................724 Removing closure cap for selector force mechanism ....................................................................725 Installing closure cap for selector force mechanism.....................................................................726 Tightening torques...............................................................................................................................726

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03 50 00 Annual maintenance USA............................................................................................................727 03 50 00 Annual maintenance as of MY 2004...........................................................................................729 03 50 00 Annual maintenance USA as of MY 2004...............................................................................730 37 02 35 Checking and topping up the ATF.................................................................................................731 Tools....................................................................................................................................................731 Checking and topping up the ATF.......................................................................................................731 Tightening torques...............................................................................................................................733 37 02 55 Replacing ATF fluid........................................................................................................................734 Tools....................................................................................................................................................734 Replacing ATF fluid............................................................................................................................734 Tightening torques...............................................................................................................................736 37 08 19 Removing and installing selector support ......................................................................................737 Removing and installing selector support............................................................................................737 Removing selector support............................................................................................................737 Installing selector support.............................................................................................................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 support.............................................................................................................743 Tightening torques...............................................................................................................................744 37 35 27 Removing and refitting the transmission.......................................................................................746 Tools....................................................................................................................................................746 Removing transmission ........................................................................................................................747 Refitting transmission..........................................................................................................................748 Tightening torques...............................................................................................................................749 37 58 19 Removing and installing ATF filter ................................................................................................750 Tools....................................................................................................................................................750 Removing ATF filter...........................................................................................................................750 Installing ATF filter.............................................................................................................................751 Tightening torques...............................................................................................................................752 38 77 19 Removing and installing electrohydraulic control unit................................................................753 Tools....................................................................................................................................................753 Removing the electrohydraulic control unit........................................................................................753 Installing the electrohydraulic control unit..........................................................................................756 Tightening torques...............................................................................................................................758

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38 77 37 Disassembling and assembling electrohydraulic control unit ......................................................759 Tools....................................................................................................................................................759 Overview..............................................................................................................................................759 Disconnecting hydraulic and electrical control unit............................................................................761 Removing solenoid and control valve ..................................................................................................761 Installing solenoid and control valve...................................................................................................761 Reassembling the hydraulic and electrical control unit.......................................................................761 40 41 19 Removing and installing the front drive shaft ...............................................................................763 Tools....................................................................................................................................................763 Removal...............................................................................................................................................763 Installation...........................................................................................................................................765 40 85 19 Removing and installing front spring strut...................................................................................766 Removal...............................................................................................................................................766 Installation...........................................................................................................................................767 42 58 19 Removing and installing rearwheel bearing ................................................................................769 Tools....................................................................................................................................................769 Removing and installing rearwheel bearing ................................................................................769 Notes on removal and installation ........................................................................................................770 Removal .........................................................................................................................................771 Installation.....................................................................................................................................772 42 71 19 Removing and installing rear spring strut .....................................................................................773 Removal...............................................................................................................................................773 Installation...........................................................................................................................................773 44 05 19 Removing and installing the wheel Turbo and GT2 ..................................................................775 Wheel mounting Turbo and GT2 ......................................................................................................775 Removing/installing the wheel on vehicle Turbo and GT2 ..............................................................775 44 35 19 Removing and installing valve (steel valve) (Turbo ll wheel)......................................................778 General.................................................................................................................................................778 Notes on removal and installation ........................................................................................................778 Removal...............................................................................................................................................779 Installation...........................................................................................................................................779 45 11 19 Removing and installing front speed sensors................................................................................781 Removal...............................................................................................................................................781 Installation...........................................................................................................................................781 45 15 19 Removing and installing rear speed sensors ..................................................................................782 Removal...............................................................................................................................................782 Installation...........................................................................................................................................782

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45 30 19 Removing and installing hydraulic unit .........................................................................................784 Replacing the hydraulic unit................................................................................................................784 Removal...............................................................................................................................................785 Installation...........................................................................................................................................786 45 59 19 Removing and installing rateofturn sensor...............................................................................788 Removal...............................................................................................................................................789 Installation...........................................................................................................................................790 45 59 31 Conversion of rateofturn sensor................................................................................................791 Overview of rateofturn sensor conversion......................................................................................792 Removal...............................................................................................................................................794 Fitting...................................................................................................................................................796 45 60 19 Removing and installing steering angle sensor.............................................................................799 Notes on steering wheel position during removal and installation......................................................799 Removal...............................................................................................................................................799 Notes on replacing the steering angle sensor vehicles prior to '03 model........................................801 Component overview....................................................................................................................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 brake pads......................................................................810 Removal...............................................................................................................................................810 Installation...........................................................................................................................................811 Bedding in the brake pads.............................................................................................................812 46 38 20 Removing and installing the rear disc brake pads ........................................................................813 Removal...............................................................................................................................................813 Installation...........................................................................................................................................814 Bedding in the brake pads.............................................................................................................815 46 50 04 Measuring front brake discs...........................................................................................................816 Measuring the front brake disc lateral runout......................................................................................816 Measuring the brake disc thickness tolerance...............................................................................817 Removing and installing the front brake disc..............................................................................................818 Removal...............................................................................................................................................818 Installation...........................................................................................................................................818 46 53 04 Measuring rear brake discs .............................................................................................................820 Measuring the rear brake disc lateral runout ........................................................................................820 Measuring the brake disc thickness tolerance...............................................................................821 xxvi

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46 53 19 Removing and installing the rear brake disc .................................................................................822 Removal...............................................................................................................................................822 Installation...........................................................................................................................................822 46 83 16 Adjusting the parking brake shoes .................................................................................................824 Check the free play of the parking brake lever....................................................................................824 Adjusting the parking brake.................................................................................................................824 46 83 19 Removing and installing the parking brake shoes........................................................................826 Removal...............................................................................................................................................826 Installation...........................................................................................................................................826 47 01 07 Bleeding brakes (vehicle with PSM)...............................................................................................829 PSM.....................................................................................................................................................829 Procedure for bleeding.........................................................................................................................829 1st step: Bleed brakes as usual.............................................................................................................829 2nd step: Bleeding at front on right with running booster pump.........................................................830 47 08 55 Changing brake fluid.......................................................................................................................832 Procedure for changing brake fluid ......................................................................................................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 installing steering wheel .........................................................................................844 Removal...............................................................................................................................................844 Installation...........................................................................................................................................845 48 90 19 Removing and installing steering gear...........................................................................................846 Removal...............................................................................................................................................846 Installation...........................................................................................................................................847 Notes for sliding piece and airbag contact unit.............................................................................848 50 55 19 Removing and installing the wing..................................................................................................850 50 56 19 Removing and installing wheel housing liners, front ....................................................................854 53 69 19 Removing and installing wheel housing liners, rear.....................................................................856 55 10 37 Disassembling and assembling release for front lid......................................................................858 Disassembling release for front cover ..................................................................................................858 Assembling release for front cover......................................................................................................860 Removing and installing support for cap release..........................................................................861 xxvii

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55 10 37 Disassembling and assembling release for front lid Removing and installing support for cap release.................................................................................861 55 17 19 Removing and installing front lower part of lid lock ....................................................................863 Removing and installing bowden cable for lock actuation..................................................................865 55 22 19 Removing and installing front lid...................................................................................................868 55 22 37 Disassembling and assembling front lid .........................................................................................870 55 25 19 Removing and installing front lid hinge .........................................................................................873 55 37 19 Removing and installing filler flap.................................................................................................875 55 57 37 Disassembling and assembling release for rear lid.......................................................................878 Disassembling release for rear lid........................................................................................................878 Assembling release for rear lid............................................................................................................880 55 86 19 Removing and installing lower part of lid lock.............................................................................882 55 90 19 Removing and installing rear lid....................................................................................................885 55 90 37 Disassembling and assembling 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 37 19 Removing and installing inner door release (bowden cable) for door lock................................900 57 45 19 Removing and installing door handle............................................................................................903 Removing and installing orientation lighting (LED lightemitting diodes) ........................................905 Removing orientation lighting (LED lightemitting diodes) ........................................................905 Installing orientation lighting (LED lightemitting diodes).........................................................906 60 14 15 Reteaching the lifting/sliding roof drive......................................................................................908 60 14 19 Removing and installing lifting/sliding roof drive........................................................................909 Removing lifting/sliding roof drive.....................................................................................................909 Installing lifting/sliding roof drive.......................................................................................................910 Emergency operation on lifting/sliding roof drive ...............................................................................911 60 28 19 Removing and installing frame for sliding roof............................................................................912 Removing frame for sliding roof.........................................................................................................912 Installing frame for sliding roof...........................................................................................................914 xxviii

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60 28 19 Removing and installing frame for sliding roof Tightening torques .........................................................................................................................916 60 28 37 Disassembling and assembling frame for sliding roof..................................................................917 Disassembling frame for sliding roof..................................................................................................917 Assembling frame for sliding roof.......................................................................................................919 60 40 19 Removing and installing sliding roof panel...................................................................................921 Additional instructions for removing the inner panels........................................................................924 Additional instructions for fitting the inner panels..............................................................................925 63 10 19 Removing and installing front bumper..........................................................................................927 Removing and installing front bumper................................................................................................927 63 15 19 Removing and installing front spoiler............................................................................................930 Removing front spoiler........................................................................................................................930 Installing front spoiler..........................................................................................................................932 63 15 37 Disassembling and assembling front spoiler ..................................................................................934 Disassembling front spoiler.................................................................................................................935 Removing 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 instructions for installation of the bumper.........................................................945 Adjustment dimensions of the bumper ..........................................................................................945 Correct assembly of the heat shields.............................................................................................946 Additional assembly instructions for installation of the bumper Carrera 4S...................................947 Correct assembly of the heat shields.............................................................................................947 Removing and installing frame with heat shield...........................................................................948 Tightening torques...............................................................................................................................949 63 55 19 Removing and installing rear spoiler.............................................................................................950 Removing rear spoiler..........................................................................................................................950 Install rear spoiler................................................................................................................................952 63 55 37 Disassembling and assembling rear spoiler...................................................................................954 Disassembling rear spoiler...................................................................................................................954 Assembling rear spoiler.......................................................................................................................956 Additional instructions for replacing the rear spoiler..........................................................................958 64 86 01 Checking function of heating for rear window.............................................................................960 Check with the temperature probe.......................................................................................................960

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64 86 19 Removing and installing rear window...........................................................................................961 Removing rear window........................................................................................................................961 Preparing the window section for installation.....................................................................................963 Installing rear window.........................................................................................................................964 Overview of tools and materials..........................................................................................................967 66 13 19 Removing and installing air inlet ....................................................................................................969 Removing air inlet...............................................................................................................................969 Installing air inlet.................................................................................................................................970 66 36 19 Removing and installing roof joint strip........................................................................................973 Removing roof joint strip.....................................................................................................................973 Installing roof joint strip......................................................................................................................975 66 58 19 Removing and installing rear spoiler.............................................................................................977 Removing rear spoiler..........................................................................................................................977 Installing rear spoiler...........................................................................................................................979 66 78 01 Checking function of heating for mirror glass..............................................................................982 Check with the temperature probe.......................................................................................................982 66 89 19 Removing and installing rearview 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...............................................................989 68 23 19 Removing and installing sun visors................................................................................................991 Removing sun visors............................................................................................................................991 Installing sun visors.............................................................................................................................992 68 23 37 Disassembling and assembling sun visor.......................................................................................993 Disassembling sun visor......................................................................................................................993 Assembling sun visor...........................................................................................................................995 68 27 13 Bonding on the interior rearview mirror .......................................................................................997 Bonding the assembled interior mirror onto the windscreen...............................................................997 68 27 19 Removing and installing the interior rearview mirror...............................................................1000 Removing the interior rearview mirror..............................................................................................1000 Installing the interior rearview mirror ................................................................................................1002 69 53 19 Removing and installing the triggering unit for the airbag.......................................................1004 Removing triggering unit for airbag..................................................................................................1004 Installing triggering unit for airbag....................................................................................................1005

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69 54 19 Removing and installing the contact unit....................................................................................1006 Installing contact unit .........................................................................................................................1006 Installing contact unit .........................................................................................................................1006 69 58 19 Removing and installing the driver's airbag unit.......................................................................1008 Removing driver's airbag unit............................................................................................................1008 Installing driver's airbag unit.............................................................................................................1008 69 59 19 Removing and installing the passenger's airbag unit.................................................................1010 Removing passenger's airbag unit ......................................................................................................1010 Installing passenger s airbag unit.....................................................................................................1011 69 63 19 Removing and installing the side airbag unit..............................................................................1012 Removing side airbag unit.................................................................................................................1012 Installing side airbag unit...................................................................................................................1013 Removing sensor for side airbag unit..........................................................................................1013 70 18 19 Removing and installing the instrument panel and instrument panel bracket ........................1015 Removing and installing the instrument panel..................................................................................1015 Removing and installing the instrument panel bracket......................................................................1017 Tightening torque...............................................................................................................................1019 Tools and materials............................................................................................................................1019 70 18 37 Disassembling and assembling 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 the regulator for wiping interval ..................................................................................1032 Installing the cigarette lighter......................................................................................................1032 Additional assembly notes for the cover and center nozzle for the instrument panel as of model year 2002 ................................................................................................................................1033 Removing cover and center nozzle for the instrument panel......................................................1033 Removing holder.........................................................................................................................1034 Installing holder ...........................................................................................................................1034 Installing cover and center nozzle for the instrument panel ........................................................1035 70 22 19 Removing and installing cowl panel cover ...................................................................................1037 Removing and installing cowl panel cover........................................................................................1037 70 59 19 Removing and installing door trim panel....................................................................................1040 Removing door trim panel.................................................................................................................1040 Installing door trim panel...................................................................................................................1042 Installation note for door sealing film ................................................................................................1044 Installation note on door sealing film for vehicles without side airbag......................................1044 Notes on the installation of partly detached door sealing films..................................................1044 Fitting sliding strip on the inner door panel.......................................................................................1045 Materials and tools.............................................................................................................................1046 xxxi

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70 59 19 Removing and installing door trim panel Tightening torque...............................................................................................................................1046 70 65 19 Removing and installing oddments compartment lid.................................................................1047 Removing and installing oddments compartment lid........................................................................1047 70 84 19 Removing and installing roof lining.............................................................................................1050 Removing roof lining.........................................................................................................................1050 Installing roof lining..........................................................................................................................1052 80 23 19 Removing and installing heat exchanger.....................................................................................1055 Removing heat exchanger..................................................................................................................1055 Installing heat exchanger...................................................................................................................1055 85 30 19 Removing and installing heater/freshair blower motor...........................................................1056 Removing heater/freshair blower motor..........................................................................................1056 Installing heater/freshair blower motor...........................................................................................1057 87 01 19 Removing and installing the heating/airconditioning unit .......................................................1058 Removing heating/airconditioning unit...........................................................................................1058 Installing heating/airconditioning unit .............................................................................................1060 87 02 19 Removing and installing the heating/airconditioning control.................................................1062 Removing heating/airconditioning control......................................................................................1062 Performing system test .......................................................................................................................1062 Tests...................................................................................................................................................1063 87 03 17 Assembly work on the airconditioning system ..........................................................................1064 Service unit SECU 134......................................................................................................................1064 Assembly work involving the refrigerant system..............................................................................1066 General assembly sequence...............................................................................................................1066 Removing refrigerant by suction and cleaning..................................................................................1067 Cleaning the refrigerant.....................................................................................................................1068 Draining off old refrigerant oil..........................................................................................................1068 Evacuating ..........................................................................................................................................1069 Topping up with new refrigerant oil..................................................................................................1070 Filling via the highpressure side......................................................................................................1070 Refilling the airconditioning system ................................................................................................1071 Distribution of the oil quantity in the refrigerant circuit ....................................................................1072 87 20 19 Removing and installing drive motors.........................................................................................1073 Removing drive motors.....................................................................................................................1073 Removing drive motor for temperature valve and central valve.................................................1073 Removing drive motor for footwell/defrost................................................................................1074 Removing drive motor for freshair/recirculation valve............................................................1074 Installing drive motors.......................................................................................................................1074 Installing drive motor for temperature valve, central valve and footwell/defrost.......................1074 Installing drive motor for freshair/recirculation valve..............................................................1075 xxxii

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87 27 19 Removing and installing the magnetic coupling.........................................................................1076 Removing the magnetic coupling......................................................................................................1076 Installing the magnetic coupling........................................................................................................1076 Checking the air gap of the magnet coupling..............................................................................1077 87 34 19 Removing and installing the compressor.....................................................................................1078 Removing the compressor ..................................................................................................................1078 Installing the compressor...................................................................................................................1079 Runningin regulations for new compressor..............................................................................1080 87 50 19 Removing and installing the condenser.......................................................................................1081 Removing the condenser....................................................................................................................1081 Installing the condenser.....................................................................................................................1081 87 53 19 Removing and installing fan for condenser.................................................................................1083 Removing fan for condenser..............................................................................................................1083 Installing fan for condenser...............................................................................................................1083 87 55 19 Removing and installing the fluid tank........................................................................................1084 Removing fluid tank..........................................................................................................................1084 Installing fluid tank............................................................................................................................1084 87 58 19 Removing 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 sensor .................................................................1086 Removing outside temperature sensor...............................................................................................1086 Installing outside temperature sensor .................................................................................................1086 87 70 19 Removing and installing the expansion valve ..............................................................................1087 Removing expansion valve................................................................................................................1087 Installing expansion valve ..................................................................................................................1087 87 78 19 Removing and installing blower driver ........................................................................................1088 Removing blower driver....................................................................................................................1088 Installing blower driver......................................................................................................................1088 87 82 19 Removing and installing interior temperature sensor................................................................1089 Removing interior temperature sensor...............................................................................................1089 Installing interior temperature sensor................................................................................................1089 87 83 19 Removing and installing pressure switch for the airconditioning system..............................1090 Removing pressure switch for the airconditioning system ..............................................................1090 Installing pressure switch for the airconditioning system...............................................................1090

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90 12 15 Setting ahead the total mileage counter in the instrument cluster............................................1091 Setting ahead with the Porsche System Tester 2...............................................................................1091 90 25 37 Disassembling and assembling instrument cluster.....................................................................1092 90 50 19 Removing and installing horn.......................................................................................................1093 Removing horn..................................................................................................................................1093 Installing horn....................................................................................................................................1094 91 12 15 Adjusting (calibrating) PCM navigation unit.............................................................................1095 GPS receiver......................................................................................................................................1095 Distance sensor..................................................................................................................................1095 Gyroscope..........................................................................................................................................1096 Procedure after commissioning ..........................................................................................................1096 Procedure after changing a tyre.........................................................................................................1096 Procedure after the power supply has been interrupted.....................................................................1096 91 12 19 Removing and installing navigation unit.....................................................................................1097 Removing navigation unit..................................................................................................................1097 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 car radio.........................................................................................1101 Removing the car radio......................................................................................................................1101 Installing the car radio.......................................................................................................................1101 Entering the code number..................................................................................................................1102 91 47 19 Removing and installing radio antenna.......................................................................................1103 Removing radio antenna....................................................................................................................1103 Installing radio antenna......................................................................................................................1103 91 57 15 Setting handsfree microphone to the telephone type ................................................................1104 Setting................................................................................................................................................1104 91 57 19 Removing and installing handsfree microphone......................................................................1105 Removing handsfree microphone....................................................................................................1105 Installing handsfree microphone.....................................................................................................1106 91 75 19 Removing and installing sensor for ParkAssistent.....................................................................1107 Removing sensor for ParkAssistent...................................................................................................1107 Installing sensor for ParkAssistent .....................................................................................................1107 ParkAssistent control module............................................................................................................1108

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92 15 19 Removing and installing the wiper motor...................................................................................1109 Removing wiper motor......................................................................................................................1109 Installing wiper motor........................................................................................................................1109 92 19 19 Removing and installing the wiper link.......................................................................................1111 Removing wiper link.........................................................................................................................1111 Installing wiper link...........................................................................................................................1111 92 27 19 Removing and installing the wiper blades...................................................................................1113 92 30 19 Removing and installing rear window wiper system..................................................................1114 Removing rear window wiper system ................................................................................................1114 Installing rear window wiper system.................................................................................................1114 92 56 19 Removing and installing pump for windscreen washer system.................................................1115 Removing pump for windscreen washer system...............................................................................1115 Installing pump for windscreen washer system.................................................................................1115 92 60 19 Removing and installing tank for windscreen washer system...................................................1116 Removing tank for windscreen washer system (7 litres)...................................................................1116 Removing tank for windscreen washer system (3 litres)...................................................................1116 Installing 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 and installing cover for spray nozzle.........................................................................1119 Removing cover for spray nozzle......................................................................................................1119 Installing cover for spray nozzle........................................................................................................1119 92 72 19 Removing and installing spray nozzle for headlight washing system.......................................1120 Removing spray nozzle for headlight washing system......................................................................1120 Installing spray nozzle for headlight washing system.......................................................................1120 92 78 19 Removing and installing pump for headlight washing system..................................................1121 Removing pump for headlight washing system.................................................................................1121 Installing pump for headlight washing system..................................................................................1121 94 05 19 Removing and installing main light switch ..................................................................................1122 Removing main light switch..............................................................................................................1122 Installing main light switch ................................................................................................................1123 94 15 01 Troubleshooting on the Xenon headlight .....................................................................................1124 94 15 05 Main headlights basic adjustment in the body .........................................................................1125 Adjustment instructions.....................................................................................................................1125 Adjustment procedure........................................................................................................................1126 xxxv

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94 15 15 Left / right traffic conversion for Xenon headlights...................................................................1127 Converting Xenon headlights............................................................................................................1127 Installation.........................................................................................................................................1127 94 15 19 Removing and installing the main headlights.............................................................................1129 94 23 19 Removing and installing gas discharge lamp (Xenon headlights).............................................1130 Removing gas discharge lamp (Xenon headlights)...........................................................................1130 Installing gas discharge lamp (Xenon headlights).............................................................................1130 94 27 19 Removing and installing bulb for parking light..........................................................................1132 Removing bulb for parking light.......................................................................................................1132 Installing bulb for parking light.........................................................................................................1132 94 29 19 Removing and installing bulb for number plate light................................................................1133 Removing bulb for number plate light...............................................................................................1133 Installing bulb for number plate light................................................................................................1133 94 33 19 Removing and installing bulb for tail light..................................................................................1134 Removing bulb for tail light ...............................................................................................................1134 Installing bulb for tail light................................................................................................................1134 94 47 19 Removing 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 direction indicator light................................................1136 Removing bulb for side direction indicator light...............................................................................1136 Installing bulb for side direction indicator light................................................................................1136 94 57 19 Removing and installing control module for gas discharge lamp.............................................1137 Removing control module for gas discharge lamp............................................................................1137 Installing control module for gas discharge lamp..............................................................................1138 94 66 19 Removing and installing bulb for auxiliary headlight (high beam headlight).........................1139 Removing bulb for auxiliary headlight..............................................................................................1139 Installing bulb for auxiliary headlight ................................................................................................1139 94 67 19 Removing and installing bulb for fog light..................................................................................1140 Removing bulb for fog light..............................................................................................................1140 Installing bulb for fog light................................................................................................................1140 94 70 19 Removing and installing bulb for additional brake light...........................................................1141 Removing bulb for additional brake light..........................................................................................1141 Installing bulb for additional brake light...........................................................................................1141

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94 78 19 Removing and installing front angle sensor for headlight beam adjustment ...........................1142 Removing front angle sensor for headlight beam adjustment...........................................................1142 Installing front angle sensor for headlight beam adjustment.............................................................1142 94 79 19 Removing and installing rear angle sensor for headlight beam adjustment............................1144 Removing rear angle sensor for headlight beam adjustment.............................................................1144 Installing rear angle sensor for headlight beam adjustment ...............................................................1144 94 94 19 Removing and installing drive motor for headlight beam adjustment.....................................1146 Removing drive motor for headlight beam adjustment.....................................................................1146 Installing drive motor for headlight beam adjustment.......................................................................1146 94 98 19 Removing and installing control module for headlight beam adjustment...............................1147 Removing control module for headlight beam adjustment................................................................1147 Installing control module for headlight beam adjustment.................................................................1147 96 16 19 Removing and installing bulb for door warning light................................................................1148 Removing bulb 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 interior light.........................................................................................................1149 96 41 19 Removing and installing bulb for luggage compartment light..................................................1150 Removing bulb for luggage compartment light.................................................................................1150 Installing bulb for luggage compartment light ...................................................................................1150 96 43 19 Removing and installing bulb for engine compartment light....................................................1151 Removing bulb for engine compartment light...................................................................................1151 Installing bulb for engine compartment light .....................................................................................1151 96 62 01 Radio remote control in handheld transmitter does not function ...........................................1152 Empty battery in handheld transmitter............................................................................................1152 Radio transmitter outside lockin range............................................................................................1152 Atmospheric interference or interfering transmitters .........................................................................1152 Energysaving mode active...............................................................................................................1153 Fault in handheld transmitter or vehicle..........................................................................................1153 96 62 37 Disassembling and assembling handheld transmitter..............................................................1154 Removing key from the bottom part..................................................................................................1154 Installing key in the bottom part........................................................................................................1154 96 62 55 Teaching handheld transmitter..................................................................................................1155 General...............................................................................................................................................1155 Work preparation...............................................................................................................................1155 Procedure...........................................................................................................................................1156

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96 72 19 Removing and installing signal converter/immobilizer..............................................................1158 Removing signal converter/immobilizer ............................................................................................1158 Installing signal converter/immobilizer.............................................................................................1159 96 85 19 Removing and installing passenger compartment monitoring sensor......................................1160 Removing and installing passenger compartment monitoring sensor...............................................1160 Removing and installing passenger compartment monitoring sensor...............................................1160 97 09 41 Repair of main wiring harness ......................................................................................................1162 Removing main wiring harness.........................................................................................................1162 Installing main wiring harness...........................................................................................................1163 97 25 41 Repair of rear wiring harness.......................................................................................................1165 Removing rear wiring harness...........................................................................................................1165 Installing rear wiring harness.............................................................................................................1166 10 01 19 Removing and installing engine....................................................................................................1168 Tools for removal ...............................................................................................................................1168 Removing engine...............................................................................................................................1169 10 01 19 Removing and installing engine....................................................................................................1179 Installing engine.................................................................................................................................1179 Tightening torques: Removing and installing engine........................................................................1182 24 40 20 Removing and 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 3 ..............................................................................1184 Installing injection valves of cylinder bank 4 6 ..............................................................................1185 24 40 20 Removing and installing injection valves Engine installed.....................................................1186 Preliminary work...............................................................................................................................1186 Removing injection valves of cylinder bank 1 3............................................................................1186 Removing injection valves of cylinder bank 4 6............................................................................1190 Installing injection valves..................................................................................................................1192 24 69 19 Removing and installing oxygen sensors in front of catalytic converter..................................1200 Tools..................................................................................................................................................1200 Removing oxygen sensors in front of catalytic converter.................................................................1200 Oxygen sensor, left side :............................................................................................................1201 Oxygen sensor, right side :..........................................................................................................1202 Installing oxygen sensors in front of catalytic converter...................................................................1202 24 70 19 Removing and installing DME control module...........................................................................1204 Obtaining readout and saving vehicle data from DME control module..........................................1205 Removing DME control module ........................................................................................................1205 Installing the DME control module...................................................................................................1206 Programming the new DME control module 911 Turbo (996).........................................................1207 xxxviii

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24 70 19 Removing and installing DME control module Programming the new DME control module GT2 and version X51..............................................1208 Programming the DME control module 911 Turbo (996).................................................................1209 Programming DME control module GT2 and version X51...........................................................1210 Version (data records) 911 Turbo (996)............................................................................................1212 Version (data records) GT2............................................................................................................1213 27 60 19 Removing and installing starter (automatic transmission)........................................................1214 Removing the starter..........................................................................................................................1214 Installing the starter ............................................................................................................................1215 34 35 37 Partially disassembling transmission...........................................................................................1216 Tools..................................................................................................................................................1216 Removing transmission cover............................................................................................................1217 Disassembling front gear set..............................................................................................................1217 Overview.....................................................................................................................................1217 Disassembling gear set................................................................................................................1219 Removing 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 Tools..................................................................................................................................................1226 Assembling input shaft......................................................................................................................1227 Assembling shafts ........................................................................................................................1227 Tightening torques .......................................................................................................................1228 Installing input and output shaft........................................................................................................1228 Installing shafts ............................................................................................................................1228 Tightening torques .......................................................................................................................1231 Fitting gear housing...........................................................................................................................1232 Fitting housing .............................................................................................................................1232 Tightening torques .......................................................................................................................1232 Assembling front gear set..................................................................................................................1232 Assembling gear set .....................................................................................................................1232 Tightening torques .......................................................................................................................1234 Fitting front transmission case cover.................................................................................................1235 Fitting cover................................................................................................................................1235 Tightening torques .......................................................................................................................1235 35 50 19 Removing and installing sealing ring for input shaft.................................................................1236 Tools..................................................................................................................................................1236 Removing sealing ring for input shaft...............................................................................................1236 Installing sealing ring for input shaft.................................................................................................1237 Tightening torques.............................................................................................................................1238 xxxix

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37 04 19 Removing and installing selector knob........................................................................................1240 Removing selector knob....................................................................................................................1240 Installing selector knob......................................................................................................................1240 37 30 19 Removing and installing Tiptronic control module....................................................................1242 Removing the control module ............................................................................................................1242 Installing the control module.............................................................................................................1244 Coding the Tiptronic control module .................................................................................................1245 Tightening torques.............................................................................................................................1246 Tools..................................................................................................................................................1246 39 02 19 Removing and installing cardan shaft ..........................................................................................1248 Tools..................................................................................................................................................1248 Removing cardan shaft......................................................................................................................1248 Installing cardan shaft........................................................................................................................1249 Tightening torques.............................................................................................................................1250 39 02 19 Removing and installing cardan shaft ..........................................................................................1251 Tools..................................................................................................................................................1251 Removing and installing cardan shaft................................................................................................1251 Removing cardan shaft................................................................................................................1251 Installing cardan shaft.................................................................................................................1252 Tightening torques.............................................................................................................................1253 39 22 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 39 22 19 Removing and installing sealing ring for short flanged shaft....................................................1256 Tools..................................................................................................................................................1256 Removing and installing sealing ring for short flanged shaft............................................................1256 Removing sealing ring for short flanged shaft............................................................................1256 Installing sealing ring for short flanged shaft ..............................................................................1258 Tightening torques.............................................................................................................................1258 39 25 19 Removing and installing long flanged shaft .................................................................................1259 Tools..................................................................................................................................................1259 Removing and installing long flanged shaft......................................................................................1259 Removing long flanged shaft......................................................................................................1259 Installing long flanged shaft........................................................................................................1260 Tightening torques.............................................................................................................................1260 39 58 19 Removing and installing lid for front wheel drive......................................................................1262 Tools..................................................................................................................................................1262 Removing the lid for front wheel drive ..............................................................................................1262 Installing the lid for front wheel drive...............................................................................................1263 xl

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39 58 19 Removing and installing lid for front wheel drive Tightening torques.............................................................................................................................1263 39 58 19 Removing and installing lid for front wheel drive......................................................................1264 Tools..................................................................................................................................................1264 Removing the lid for front wheel drive ..............................................................................................1264 Installing the lid for front wheel drive...............................................................................................1265 Tightening torques.............................................................................................................................1265 39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive).............................1266 Tools..................................................................................................................................................1266 Removing the sealing ring for the flanged shaft (front wheel drive) .................................................1266 Installing the sealing ring for the flanged shaft (front wheel drive)..................................................1267 39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive).............................1269 Tools..................................................................................................................................................1269 Removing the sealing ring for the flanged shaft (front wheel drive) .................................................1269 Installing the sealing ring for the flanged shaft (front wheel drive)..................................................1270 39 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 conditions...................................................................................................................................1275 Checking function of installed viscous clutch...................................................................................1275 39 60 19 Removing and installing the viscous clutch.................................................................................1278 Tools..................................................................................................................................................1278 Removing the viscous clutch.............................................................................................................1279 Installing the viscous clutch...............................................................................................................1279 Tightening torques.............................................................................................................................1280 39 60 19 Removing and installing the viscous clutch.................................................................................1281 Tools..................................................................................................................................................1281 Removing the viscous clutch.............................................................................................................1282 Installing the viscous clutch...............................................................................................................1282 Tightening torques.............................................................................................................................1283 39 62 19 Removing and installing support for front wheel drive.............................................................1284 Removing the support for front wheel drive......................................................................................1284 Installing the support for front wheel drive.......................................................................................1284 Tightening torques.............................................................................................................................1285 39 62 19 Removing and installing support for front wheel drive.............................................................1286 Removing the support for front wheel drive......................................................................................1286 Installing the support for front wheel drive.......................................................................................1286 Tightening torques.............................................................................................................................1287 xli

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39 82 19 Removing and installing sealing ring for cardan flange .............................................................1288 Tools..................................................................................................................................................1288 Removing sealing ring for cardan flange...........................................................................................1288 Installing sealing ring for cardan flange............................................................................................1289 Tightening torques.............................................................................................................................1290 39 82 19 Removing and installing sealing ring for cardan flange .............................................................1291 Tools..................................................................................................................................................1291 Removing and installing sealing ring for cardan flange....................................................................1291 Removing sealing ring for cardan flange....................................................................................1291 Installing sealing ring for cardan flange......................................................................................1292 Tightening torques.............................................................................................................................1293 39 88 19 Removing and installing front wheel drive ..................................................................................1294 Remove front wheel drive ..................................................................................................................1294 Installing the front wheel drive..........................................................................................................1295 Tightening torques.............................................................................................................................1296 39 88 19 Removing and installing front wheel drive ..................................................................................1297 Removing front wheel drive..............................................................................................................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 Tightening torques.............................................................................................................................1302 39 90 55 Changing transmission oil in front wheel drive..........................................................................1303 Changing transmission oil in front wheel drive.................................................................................1303 Tightening torques.............................................................................................................................1303 39 90 55 Changing transmission oil in front wheel drive..........................................................................1305 Changing transmission oil in front wheel drive.................................................................................1305 Tightening torques.............................................................................................................................1305 42 21 19 Removing and installing rear drive shaft (manual transmission).............................................1307 Tools..................................................................................................................................................1307 Removing the drive shaft (manual transmission)..............................................................................1307 Installing the drive shaft (manual transmission)................................................................................1310 42 21 19 Removing and installing rear drive shaft (Tiptronic transmission) ..........................................1313 Tools..................................................................................................................................................1313 Removing the drive shaft (Tiptronic transmission)...........................................................................1313 Installing the drive shaft (Tiptronic transmission).............................................................................1316

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45 46 19 Removing and installing front ABS lead.....................................................................................1320 Removing front ABS lead ..................................................................................................................1320 Installing front ABS lead...................................................................................................................1322 Tightening torques.............................................................................................................................1324 Tools..................................................................................................................................................1324 45 46 19 Removing and installing rear ABS lead (Turbo & GT2)...........................................................1325 Removing rear ABS lead...................................................................................................................1325 Installing rear ABS lead.....................................................................................................................1327 Tightening torques.............................................................................................................................1330 Tools..................................................................................................................................................1330 46 50 02 Checking front gray cast iron brake discs (wear assessment)...................................................1331 General...............................................................................................................................................1331 1. Visual inspection for cracks and evaluating cracks.......................................................................1331 Evaluating the cracks on the gray cast iron brake discs..............................................................1332 2. Checking brake discs for minimum thickness...............................................................................1333 Notes on bedding in the new brake pads...........................................................................................1334 46 50 02 Checking front PCCB brake discs (wear assessment)................................................................1335 General...............................................................................................................................................1335 1. Visual inspection of the surfaces of the brake disc friction surfaces.............................................1335 PCCB brake disc wear appearance ..............................................................................................1336 2. Checking brake discs for minimum thickness...............................................................................1337 3. Checking brake discs 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 assessment)....................................................1339 General...............................................................................................................................................1339 1. Visual inspection for cracks and evaluating cracks.......................................................................1339 Evaluating the cracks on the gray cast iron brake discs..............................................................1340 2. Checking brake discs for minimum thickness...............................................................................1341 Notes on bedding in the new brake pads...........................................................................................1342 46 53 02 Checking rear PCCB brake discs (wear assessment).................................................................1343 General...............................................................................................................................................1343 1. Visual inspection of the surfaces of the brake disc friction surfaces.............................................1343 PCCB brake disc wear appearance ..............................................................................................1344 2. Checking brake discs for minimum thickness...............................................................................1345 3. Checking brake discs for edge damage ..........................................................................................1345 Note concerning bores (perforations) in the brake disc friction surface ............................................1346 Note on bedding in the new brake pads.............................................................................................1346 50 10 55 Replacing closing panel.................................................................................................................1347 Cutting out closing panel and front floor panel.................................................................................1347 Preparing closing panel and front floor panel for installation and fitting..........................................1349 Welding in closing panel and front floor panel.................................................................................1351 xliii

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50 10 55 Replacing closing panel Tools and materials............................................................................................................................1352 50 14 55 Replacing front wall.......................................................................................................................1353 Cutting out front wall.........................................................................................................................1353 Preparing front wall for installation and fitting.................................................................................1355 Welding in front wall.........................................................................................................................1357 Tools and materials............................................................................................................................1358 50 74 55 Replacing wheel housing...............................................................................................................1359 Removing wheel housing, lower shell and outer side member from the body..................................1359 Preparing wheel housing, lower shell and outer side member for installation and fitting .................1361 Welding wheel housing, lower shell and outer side members into the body .....................................1363 Tools and materials............................................................................................................................1364 50 74 56 Replacing wheel housings and side members (sectional repair)................................................1365 Cutting out wheel housings and side members..................................................................................1365 Preparing wheel housings and side members for installation and fitting..........................................1367 Welding in wheel 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 installation .....................................................1374 Welding in front inner side member..................................................................................................1376 Materials, tools ...................................................................................................................................1377 50 93 30 Cleaning front water drains on Coup and Cabriolet................................................................1379 Cleaning front water drains on Coup and Cabriolet .........................................................................1379 51 03 55 Replacing roof................................................................................................................................1382 Removing roof...................................................................................................................................1382 Preparation of roof for installation and fitting...................................................................................1384 Welding in roof..................................................................................................................................1386 Tools and materials............................................................................................................................1387 51 21 55 Replacing rear centre panel..........................................................................................................1389 Removing rear centre panel...............................................................................................................1389 Preparing the rear centre panel for installation and fitting................................................................1391 Welding in the rear centre panel........................................................................................................1392 Tools and materials............................................................................................................................1393 51 45 55 Replacing lower side member.......................................................................................................1395 Cutting out lower side member..........................................................................................................1395 Preparation for installation of lower side member and fitting...........................................................1397 Welding in lower side member..........................................................................................................1399 Tools and materials............................................................................................................................1400

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51 45 55 Replacing lower side member Cabriolet ...................................................................................1401 Cutting out lower side member..........................................................................................................1401 Preparation for installation of lower side member and fitting...........................................................1403 Welding in lower side member..........................................................................................................1405 Tools and materials............................................................................................................................1406 51 63 19 Removing and installing deformation element ............................................................................1407 Removing deformation element .........................................................................................................1407 Installing deformation element..........................................................................................................1408 51 87 55 Replacing seat cross member........................................................................................................1409 Cutting out seat cross member...........................................................................................................1409 Preparation of seat cross member for installation and fitting............................................................1411 Welding in seat cross member...........................................................................................................1413 Tools and materials............................................................................................................................1414 51 90 19 Removing and installing underside panel....................................................................................1415 Removing and installing front cover ..................................................................................................1415 Removing and installing middle cover..............................................................................................1417 Removing and installing rear trim.....................................................................................................1418 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............................................................................................................................1424 53 55 55 Replacing side section....................................................................................................................1425 Cutting through side section..............................................................................................................1425 Preparing side section for installation and fitting..............................................................................1428 Welding in the side section................................................................................................................1430 Flanging the wheel arch edges GT2...............................................................................................1433 Tools and materials............................................................................................................................1433 53 93 30 Cleaning rear water drains on Coupe and Cabriolet.................................................................1435 Cleaning rear water drains on Coupe and Cabriolet..........................................................................1435 55 62 19 Removing and installing front emergency release as of MY 2003.........................................1438 Checking inner release of luggage compartment (Trunk Entrapment) ..............................................1440 55 84 19 Removing and installing engine cover release.............................................................................1441 Checking inner release of luggage compartment (Trunk Entrapment) ..............................................1441 Removing engine cover release.........................................................................................................1441 Installing engine cover release...........................................................................................................1442 57 51 16 Setting the door..............................................................................................................................1444

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57 51 19 Removing and installing door.......................................................................................................1446 57 51 37 Disassembling and assembling door.............................................................................................1450 Disassembling door ............................................................................................................................1450 Assembling door................................................................................................................................1456 57 51 37 Disassembling and assembling door.............................................................................................1462 Diagram: sheetmetal clips and grommets..........................................................................................1462 Basic setting of door lock..................................................................................................................1463 Basic setting of the door lock before installation........................................................................1464 Standardising the system...................................................................................................................1465 Standardising the power windows ...............................................................................................1465 Blockage detection function........................................................................................................1465 Precondition for operation of the power windows......................................................................1465 Fitting the door window in the clamping jaws..................................................................................1465 Adjusting the door window angle in the vehicle's longitudinal direction ..........................................1466 Adjusting the door window height .....................................................................................................1466 Adjustment procedure:................................................................................................................1467 Checking the adjustment.............................................................................................................1467 Adjustment of the door window pressing force on the door seal at the top and 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 Preparing the window section for installation...................................................................................1472 Preparing the windscreen for installation..........................................................................................1473 Fitting windscreen ..............................................................................................................................1475 Overview of tools and materials........................................................................................................1478 64 54 19 Removing and installing power window motor ...........................................................................1481 Removing power window motor.......................................................................................................1481 Installing power window motor.........................................................................................................1481 Standardising the new power window motor .....................................................................................1482 Tightening torques.............................................................................................................................1482 64 71 19 Removing and installing rear power windows (Cabriolet)........................................................1483 Removing rear power windows (Cabriolet) .......................................................................................1484 Installing rear power windows (Cabriolet)........................................................................................1485 Additional instructions for adjusting or replacing the rear power window.......................................1487 Tools and materials............................................................................................................................1488 Tightening torques.............................................................................................................................1488 Test and adjusting values...................................................................................................................1488 64 75 19 Removing and installing side window..........................................................................................1489 Removing side window.....................................................................................................................1489 Installing side window.......................................................................................................................1491 xlvi

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64 75 19 Removing and installing side window Test and adjusting values...................................................................................................................1492 Tightening torques.............................................................................................................................1492 64 75 19 Removing and installing rear side window (Cabriolet)..............................................................1493 Removing side window.....................................................................................................................1493 Installing side window.......................................................................................................................1493 Tightening torques.............................................................................................................................1494 Test and adjusting values...................................................................................................................1494 64 76 19 Removing and installing side window seal ...................................................................................1495 Removing side window seal..............................................................................................................1495 Removing the retaining strip.......................................................................................................1497 Installing side window seal................................................................................................................1497 Installing the retaining strip .........................................................................................................1499 Materials and tools.............................................................................................................................1499 64 76 19 Removing and installing rear side window seal (Cabriolet)......................................................1500 Removing side window seal..............................................................................................................1500 Installing side window seal................................................................................................................1500 64 86 19 Removing and installing rear glass window 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 installing rear window (hardtop)........................................................................1507 Removing rear window (hardtop)......................................................................................................1508 Preparing the window section (hardtop) for installation ....................................................................1510 Preparing the rear window (hardtop) for installation. ........................................................................1512 Installing rear window (hardtop).......................................................................................................1513 Overview of tools and materials........................................................................................................1516 Tightening torques.............................................................................................................................1517 66 31 19 Removing and installing sill cover................................................................................................1519 Removing sill cover...........................................................................................................................1519 Installing sill cover .............................................................................................................................1521 66 72 37 Disassembling and assembling pump unit...................................................................................1523 Removing hydraulic cylinder .............................................................................................................1524 Filling the hydraulic cylinder.............................................................................................................1526 Installing hydraulic cylinder..............................................................................................................1526 Removing pump.................................................................................................................................1528 Filling the pump unit ..........................................................................................................................1529 Installing pump..................................................................................................................................1529 Bleeding the pump unit......................................................................................................................1531 Removing and installing wiring harness............................................................................................1533 xlvii

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66 72 37 Disassembling and assembling pump unit Removing wiring harness............................................................................................................1533 Installing wiring harness.............................................................................................................1534 Removing and installing micro switches for rear spoiler............................................................1536 Removing micro switches...........................................................................................................1536 Installing micro switches.............................................................................................................1537 Troubleshooting.................................................................................................................................1537 Tools and materials............................................................................................................................1538 66 85 19 Removing and installing micro switches for rear spoiler...........................................................1539 Remove micro switches.....................................................................................................................1539 Installing micro switches...................................................................................................................1540 Tools..................................................................................................................................................1540 66 89 37 Disassembling and assembling the rearview mirror ...................................................................1541 Disassembling the rearview mirror....................................................................................................1541 Assembling the rearview mirror........................................................................................................1543 68 05 19 Removing and installing inner sill (driver's side).......................................................................1546 Removing inner sill............................................................................................................................1546 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 lock......................................................................1553 Removing and installing glove compartment lock............................................................................1553 68 12 19 Removing and installing lid for glove compartment..................................................................1555 Removing lid for glove compartment................................................................................................1555 Installing lid for glove compartment ..................................................................................................1556 Replacing microswitch and interior light ...........................................................................................1557 Replacing pneumatic shock absorber .................................................................................................1558 68 15 19 Removing and installing glove compartment..............................................................................1560 Removing glove compartment...........................................................................................................1560 Installing glove compartment............................................................................................................1562 68 17 19 Removing and installing center console (front section)..............................................................1564 68 17 19 Removing and installing center console.......................................................................................1568 68 30 19 Removing and installing cup holder .............................................................................................1571 Removing cup holder.........................................................................................................................1571 Installing cup holder..........................................................................................................................1572

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69 11 19 Removing and installing front threepoint belt..........................................................................1573 Removing front threepoint belt ........................................................................................................1573 Installing front threepoint belt.........................................................................................................1575 69 11 19 Removing and installing front threepoint belt Cabriolet.....................................................1577 Removing front threepoint belt ........................................................................................................1577 Installing front threepoint belt.........................................................................................................1579 69 11 01 Checking seat belts.........................................................................................................................1581 Checking belt strap............................................................................................................................1581 Checking automatic belt device (locking effect)...............................................................................1582 Belt buckle, visual inspection............................................................................................................1583 Belt buckle, function test...................................................................................................................1583 Checking sash guides.........................................................................................................................1584 Checking mounting elements and mounting points...........................................................................1584 69 12 19 Removing and installing rear threepoint belt...........................................................................1585 Removing rear threepoint belt.........................................................................................................1585 Installing rear threepoint belt ...........................................................................................................1587 69 12 19 Removing and installing rear threepoint belt Cabriolet .......................................................1589 Removing rear threepoint belt.........................................................................................................1589 Installing rear threepoint belt ...........................................................................................................1591 69 13 19 Removing and installing belt tensioner as of MY 2002...........................................................1593 Removing belt tensioner....................................................................................................................1593 Installing belt tensioner......................................................................................................................1594 69 36 19 Removing and installing adjustment fitting (seat belt height adjuster) ....................................1596 Removing and installing adjustment fitting.......................................................................................1596 69 51 19 Removing and installing sensor for side airbag..........................................................................1598 Remove sensor for side airbag...........................................................................................................1598 Install sensor for side airbag..............................................................................................................1600 Tools..................................................................................................................................................1601 69 72 19 Removing and installing rollover bar........................................................................................1602 Safety instructions for work on the rollover protection system .......................................................1602 Mechanical emergency triggering of the rollover protection system..............................................1603 Removing rollover protection system ..............................................................................................1604 Installing rollover protection system...............................................................................................1605 Tightening torques.............................................................................................................................1607 69 74 19 Removing and installing control module for rollover protection system...............................1608 Removing control module.................................................................................................................1608 Installing control module...................................................................................................................1608 Tools and materials............................................................................................................................1609

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69 77 19 Removing and installing frame for rollover protection system...............................................1610 Removing and installing frame for rollover protection system.......................................................1610 Tightening torques.............................................................................................................................1612 70 05 19 Removing and installing front luggage compartment trim ........................................................1613 Removing and installing trims units..................................................................................................1613 Removing and installing carpet lining...............................................................................................1615 Tools and materials............................................................................................................................1616 70 18 19 Removing and installing the instrument panel and instrument panel bracket as of model year 2003 ............................................................................................................................................1617 Removing and installing the instrument panel..................................................................................1618 Removing and installing the instrument panel bracket......................................................................1619 Tightening torque...............................................................................................................................1622 Tools and materials............................................................................................................................1622 70 41 19 Removing and installing floor covering.......................................................................................1624 70 57 19 Removing and installing trim of A, B and Cpillars..................................................................1627 Removing and installing trim of A, B and Cpillars.........................................................................1627 Installing trim of A, B and Cpillars.................................................................................................1629 70 57 19 Removing and installing Apillar trim Cabriolet...................................................................1631 Removing Apillar trim .....................................................................................................................1631 Installing Apillar trim......................................................................................................................1632 Tightening torques.............................................................................................................................1634 70 75 19 Removing and installing sidepanel lining..................................................................................1635 Removing sidepanel lining..............................................................................................................1635 Installing sidepanel lining ................................................................................................................1637 70 75 19 Removing and installing sidepanel lining Cabriolet.............................................................1639 Removing sidepanel lining..............................................................................................................1639 Installing sidepanel lining ................................................................................................................1641 70 84 19 Removing and installing Cabriolet roof lining............................................................................1643 Removing roof lining, front...............................................................................................................1644 Installing front roof lining ..................................................................................................................1647 Removing rear roof lining ..................................................................................................................1649 Installing rear roof lining...................................................................................................................1650 Removing and installing side roof lining...........................................................................................1652 Removing side roof lining...........................................................................................................1652 Installing side roof lining............................................................................................................1653 Tightening torques.............................................................................................................................1653 72 01 19 Removing and installing front seat ...............................................................................................1654 Removing front seat...........................................................................................................................1654 Installing front seat............................................................................................................................1656 l

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72 21 19 Removing and installing cushion carrier.....................................................................................1658 Removing front cushion carrier.........................................................................................................1658 Installing front cushion carrier...........................................................................................................1660 72 36 19 Removing and installing motor for the lumbar support............................................................1662 Removing lumbar adjustment device for the lumbar support ............................................................1663 Removing motor for the lumbar support...........................................................................................1664 Removing electrical line for the lumbar............................................................................................1664 Removing lumbar support.................................................................................................................1664 Installling lumbar adjustment device for the lumbar support............................................................1665 Installing motor for the lumbar support.............................................................................................1666 Installing electrical line for the lumbar..............................................................................................1666 Installing lumbar support...................................................................................................................1666 Tools..................................................................................................................................................1667 Test plan for the lumbar adjustment device.......................................................................................1667 72 86 19 Removing and installing switch for seat adjustment..................................................................1668 Removing switch for seat adjustment................................................................................................1669 Installing switch for seat adjustment ..................................................................................................1670 72 87 19 Removing and installing electric motor for the seat adjustment...............................................1672 Removing electric motor for seat adjustment....................................................................................1672 Installing 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 motor for front seat height adjustment................................................................1677 Installing electric motor for front seat height adjustment..................................................................1679 Tools..................................................................................................................................................1680 Test plan for the front seat height adjustment ....................................................................................1680 72 89 19 Removing and installing electric motor for the backrest adjustment.......................................1682 Removing and installing electric motor for the backrest adjustment................................................1683 Installing electric motor for backrest adjustment ...............................................................................1684 Routing of wiring harness for the backrest adjustment.....................................................................1685 Tools..................................................................................................................................................1685 Test plan for the backrest adjustment device.....................................................................................1686 72 92 19 Removing and installing electric motor for the rear seat height adjustment...........................1687 Removing electric motor for rear seat height adjustment..................................................................1687 Installing electric motor for rear seat height adjustment...................................................................1689 Tools..................................................................................................................................................1690 Test plan for the rear seat height adjustment.....................................................................................1690 74 13 55 Replacing cover for front seat cushion .........................................................................................1692 Removing cover for the front seat.....................................................................................................1692 Installing cover for the seat cushion..................................................................................................1694 li

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74 13 55 Replacing cover for front seat cushion Tools and materials............................................................................................................................1695 74 19 19 Removing and installing centre backrest strip............................................................................1696 Removing the backrest centre strip....................................................................................................1696 Installing the backrest centre strip.....................................................................................................1698 74 19 55 Replacing covering for backrest centre strip..............................................................................1699 Removing covering for backrest centre strip.....................................................................................1699 Installing covering for backrest centre strip .......................................................................................1701 Tools and materials............................................................................................................................1702 74 27 19 Removing and installing control module for seat heating ..........................................................1703 Removing and installing control module for seat heating.................................................................1704 Seat heating line route ........................................................................................................................1704 Central plug ........................................................................................................................................1705 Removing and installing pin housing for seat heating and belt buckle.............................................1705 Tools..................................................................................................................................................1706 Test plan for the seat heating.............................................................................................................1706 90 25 19 Removing and installing instrument cluster ................................................................................1708 Removing instrument cluster.............................................................................................................1708 Installing instrument cluster ...............................................................................................................1709 Coding the instrument cluster............................................................................................................1709 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 switching on the Porsche System Tester 2........................................................1712 Device code input........................................................................................................................1713 91 10 19 Removing and installing display and operator control unit (PCM 2) as of MY 2003..........1714 Removing display and operator control unit (PCM 2) .......................................................................1714 Installing display and operator control unit (PCM 2)........................................................................1715 Teaching display and operator control unit (PCM 2)........................................................................1717 91 20 02 Checking complaints about car radio system..............................................................................1721 Malfunctions in radio system.............................................................................................................1721 Reduced sound quality in one or more loudspeakers .........................................................................1722 Remedying problems with the amplifier ............................................................................................1723 Interference noises.............................................................................................................................1724 Interference noises, checking cable connections .........................................................................1725 Interference noises due to alternator...........................................................................................1726 Interference noises due to engine................................................................................................1726 Interference noise due to antenna................................................................................................1727 Interference noises due to power supply.....................................................................................1728 Interference noises due to all looudspeakers...............................................................................1730 Electromagnetic compatibility (EMC) Troubleshooting................................................................1731 lii

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91 20 02 Checking complaints about car radio system Tools..................................................................................................................................................1732 91 24 19 Removing and installing the car radio as of MY 2003............................................................1733 Tools..................................................................................................................................................1733 Removing the car radio......................................................................................................................1733 Installing the car radio.......................................................................................................................1735 Teaching the car radio ........................................................................................................................1735 91 42 19 Removing and installing rear loudspeakers, Bose sound package............................................1738 Removing rear loudspeakers..............................................................................................................1738 Installing rear loudspeakers...............................................................................................................1739 91 44 19 Removing and installing the loudspeaker amplifier...................................................................1741 Removing the loudspeaker amplifier.................................................................................................1741 Installing the loudspeaker amplifier ...................................................................................................1743 91 74 19 Removing and installing control module for parking assistant.................................................1745 Removing control module for parking assistant................................................................................1745 Installing control module for parking assistant ..................................................................................1746 91 84 19 Removing and installing 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 for antenna..............................................................................................1749 Installing control module for antenna................................................................................................1750 91 90 19 Removing and installing control module for telephone ..............................................................1752 Removing control module for telephone...........................................................................................1752 Installing control module for telephone.............................................................................................1753 92 12 19 Removing and installing rain sensor............................................................................................1754 Removing rain sensor........................................................................................................................1754 Installing rain sensor..........................................................................................................................1757 Open circuit in the rain sensor connection (emergency interval operation)......................................1760 92 13 19 Removing and installing control module for rain sensor...........................................................1761 Removing control module for rain sensor.........................................................................................1762 Installing control module for rain sensor...........................................................................................1763 Safety function in the event of failure (engine blockage)..................................................................1764 96 64 32 Converting installation position for tilt sensor, additional alarm system M536......................1765 Tools..................................................................................................................................................1767

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96 87 19 Removing and installing control unit for alarm system.............................................................1768 Removing control unit for alarm system...........................................................................................1768 Installing control unit for alarm system.............................................................................................1770 Teaching control unit for the alarm system.......................................................................................1771 97 89 19 Removing and installing current distributor..............................................................................1773 Removing current distributor.............................................................................................................1773 Installing the current distributor .........................................................................................................1775 97 92 19 Removing and installing fusible element in the current distributor.........................................1778 Removing fusible element from the current distributor .....................................................................1778 Installing fusible element in the current distributor...........................................................................1779 911 Turbo (996) Technical Manual.............................................................................................................1780 General...............................................................................................................................................1780 Structure.............................................................................................................................................1780 Breakdown of Repair 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 diagram for 911 Turbo (996), 02 model....................................................................................1787 97 Circuit diagram for 911 Turbo (996), '03 model...................................................................................1789 97 Circuit diagram for 911 Turbo (996), '04 model...................................................................................1791 97 Circuit diagram for 911 Turbo (996), '05 model...................................................................................1793 Preconditions for using workshop documentation for Porsche vehicles.................................................1795 01 Mobile roofs: checking function.............................................................................................................1797 Checking sliding roof .........................................................................................................................1797 Checking convertible top...................................................................................................................1797 Checking the hardtop.........................................................................................................................1797 01 Glazing: visual inspection for damage...................................................................................................1799 01 Checking lid and doors............................................................................................................................1800 Checking lid lock, front and rear.......................................................................................................1800 Checking safety hook, front lid ..........................................................................................................1800 Function test, checking door lock......................................................................................................1800 Functional inspection of the tank cap lock........................................................................................1800

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01 Interior equipment: visual inspection for damage and soiling............................................................1801 01 Removing transport protection..............................................................................................................1802 1 Removing external transport protection ..........................................................................................1802 1 Removing internal transport protection..........................................................................................1803 01 Installing air guides for PCCB brake discs GT2...............................................................................1804 Installing front air guides...................................................................................................................1804 Installing rear air guides .....................................................................................................................1804 01 Fitting front lip GT2.............................................................................................................................1806 GT2............................................................................................................1807

01 Fitting sixpoint seat belt

01 Checking the Vehicle Ident. No..............................................................................................................1809 01 Checking the exterior equipment and paint finish...............................................................................1810 Checking exterior equipment.............................................................................................................1810 Checking 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 ................................................................................................................................1813 6speed manual transmission G 96.88..............................................................................................1813 Manual transmission tightening torques ......................................................................................1814 4 Running gear, general GT2...................................................................................................................1815 General...............................................................................................................................................1815 4 Notes on repair instructions GT2..........................................................................................................1817 General...............................................................................................................................................1817 Tightening torques.............................................................................................................................1817 Adjustment operations on the spring struts ........................................................................................1817 Suspension alignment........................................................................................................................1818 Wheel removal/installation................................................................................................................1818 Brake General.................................................................................................................................1819 Brake booster.....................................................................................................................................1819 4 Tests / notes GT2 .....................................................................................................................................1820 Note....................................................................................................................................................1820 Lifting platform / test stands..............................................................................................................1820 Wheel alignment platform.................................................................................................................1820 Brake test...........................................................................................................................................1820 Power test...........................................................................................................................................1820 Front and rear stabilizer setting ..........................................................................................................1821 lv

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4 Tests / notes GT2 Spoiler setting....................................................................................................................................1821 Racing camber values........................................................................................................................1822 44 Alignment card GT2.............................................................................................................................1823 Suspension alignment GT2.......................................................................................................................1825 Suspension alignment, complete ........................................................................................................1825 Driving onto measuring platform .......................................................................................................1825 Tools..................................................................................................................................................1825 Deviating points for GT2...................................................................................................................1826 Notes on height changes/wheelload changes ...................................................................................1827 Vehicle height GT2............................................................................................................................1828 Wheel alignment................................................................................................................................1829 Frontaxle camber setting...........................................................................................................1830 Camber fine adjustment ...............................................................................................................1830 Camber/toe, rear axle..................................................................................................................1831 Instructions for fitting diagonal control arm on control arm GT2 ..................................................1831 44 Tyre failure / tyre sealant GT2............................................................................................................1833 Repair procedure................................................................................................................................1833 46 Technical data/Brake wear limit GT2................................................................................................1835 Technical Data GT2 ........................................................................................................................1835 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 GT2 ...................................................................1838 Disassembly and assembly instructions.............................................................................................1839 Disassembly .................................................................................................................................1839 Preliminary work and notes on assembly....................................................................................1840 Assembly.....................................................................................................................................1840 42 Disassembling and assembling rear spring strut GT2......................................................................1843 Notes about adjustment work on the spring struts.............................................................................1843 Disassembling and assembling rear spring strut GT2....................................................................1844 Disassembly and assembly instructions.............................................................................................1846 Disassembly .................................................................................................................................1846 Preliminary work and notes on assembly....................................................................................1846 Assembly.....................................................................................................................................1847 30 01 07 Bleeding the clutch system GT2................................................................................................1850 Filling/bleeding..................................................................................................................................1850 30 45 19 Removing and installing release bearing (clutch removed) GT2...........................................1852 Removing release bearing..................................................................................................................1853 Installing release bearing...................................................................................................................1853 lvi

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30 50 19 Removing and installing clutch GT2 .........................................................................................1855 Tools..................................................................................................................................................1855 Removing clutch................................................................................................................................1855 Installing clutch ..................................................................................................................................1856 Tightening torques.............................................................................................................................1856 30 50 37 Disassembling and assembling clutch GT2..............................................................................1857 34 01 55 Changing transmission oil GT2.................................................................................................1858 Changing transmission oil GT2......................................................................................................1858 Topping up transmission oil GT2...................................................................................................1858 Tightening torques.............................................................................................................................1859 34 35 27 Removing and refitting the transmission GT2 .........................................................................1860 Tools..................................................................................................................................................1860 Removing transmission ......................................................................................................................1860 Refitting transmission........................................................................................................................1861 Tightening torques.............................................................................................................................1863 34 37 37 Disassembling and assembling transmission housing GT2 .....................................................1864 Tools..................................................................................................................................................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............................................................................................................................................1870 Disassembling gear housing..............................................................................................................1871 Disassembling gearshift..............................................................................................................1871 Removing outer bearing race......................................................................................................1872 Removing ball sleeves.................................................................................................................1872 Removing screw plug..................................................................................................................1872 Assembling gear housing...................................................................................................................1872 Assembling gearshift...................................................................................................................1873 Installing outer bearing race........................................................................................................1873 Installing ball sleeves..................................................................................................................1873 Installing screw plug...................................................................................................................1873 Tightening torques.............................................................................................................................1873 34 55 37 Disassembling and assembling front transmission cover GT2...............................................1875 Tools..................................................................................................................................................1875 Overview............................................................................................................................................1876 Disassembling front transmission case cover....................................................................................1877 Disassembling reverse idler gear .................................................................................................1877 Dismantling cylinderroller bearing...........................................................................................1877 lvii

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34 55 37 Disassembling and assembling front transmission cover GT2 Disassembling outer bearing race ................................................................................................1878 Assembling front transmission case cover .........................................................................................1879 Fitting reverse idler gear ..............................................................................................................1879 Fitting cylindricalroller bearing................................................................................................1879 Fitting outer bearing race............................................................................................................1880 Tightening torques.............................................................................................................................1880 34 72 19 Removing and installing transmission oil pump GT2.............................................................1881 Tools..................................................................................................................................................1881 Removing transmission oil pump......................................................................................................1881 Installing transmission oil pump........................................................................................................1882 Tightening torques.............................................................................................................................1882 34 74 19 Removing and installing transmission oil cooler GT2 .............................................................1883 Tools..................................................................................................................................................1883 Overview............................................................................................................................................1883 Removing transmission oil cooler.....................................................................................................1884 Installing transmission oil cooler.......................................................................................................1886 Tightening torques.............................................................................................................................1886 35 50 19 Removing and installing sealing ring for drive shaft GT2 ......................................................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 operations ....................................................................................................1893 Determining disc thickness S4 and S5...............................................................................................1893 Determining disc thickness S3...........................................................................................................1895 Determining disc thickness S1 and S2...............................................................................................1897 Determining total disc thickness S1 + S2 ....................................................................................1897 Dividing the total disc thickness into S1 and S2.........................................................................1898 Checking the circumferential backlash and setting, if necessary................................................1898 39 22 19 Removing and installing sealing ring for halfshaft flange GT2.............................................1901 Tools..................................................................................................................................................1901 Removing sealing ring for halfshaft flange.......................................................................................1901 Installing sealing ring for halfshaft flange.........................................................................................1902 Tightening torques.............................................................................................................................1903 39 40 19 Removing and installing differential and differential lock GT2............................................1904 Tools..................................................................................................................................................1904 Overview............................................................................................................................................1904 Removing differential and differential lock .......................................................................................1906 Installing diffential and differential 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39 40 19 Removing and installing differential and differential lock GT2. Tightening torques.............................................................................................................................1906 39 40 37 Assembling and disassembling differential and differential lock GT2..................................1907 Tools..................................................................................................................................................1907 Overview............................................................................................................................................1907 Disassembling GKN differential lock ................................................................................................1909 Assembling GKN differential lock....................................................................................................1909 Tightening torques.............................................................................................................................1910 46 16 24 Installing air ducts for PCCB brake discs GT2.......................................................................1912 Installing front air ducts.....................................................................................................................1912 Installing rear air ducts .......................................................................................................................1913 46 36 20 Removing and installing the front disc brake pads GT2 / Turbo with PCCB......................1914 Removal.............................................................................................................................................1915 Installation.........................................................................................................................................1917 Bedding in the brake pads...........................................................................................................1918 46 38 20 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.................................................................1923 Removal.............................................................................................................................................1923 Explanation of 2part brake disc.......................................................................................................1924 Installation.........................................................................................................................................1924 Note on bedding in the new brake pads......................................................................................1925 46 53 19 Removing and installing the rear PCCB brake disc...................................................................1926 Removal.............................................................................................................................................1926 Explanation of 2part brake disc.......................................................................................................1927 Installation.........................................................................................................................................1927 Note on bedding in the new brake pads......................................................................................1928 47 01 07 Bleeding brake GT2 ....................................................................................................................1929 General...............................................................................................................................................1929 Bleeding brakes ..................................................................................................................................1929 34 35 37 Disassembling transmission GT2..............................................................................................1931 Tools..................................................................................................................................................1931 Removing transmission cover............................................................................................................1932 Disassembling front gear set..............................................................................................................1932 Overview.....................................................................................................................................1932 Disassembling gear set................................................................................................................1934 Removing gear housing.....................................................................................................................1935 Removing input and output shaft.......................................................................................................1935 lix

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34 35 37 Disassembling transmission GT2 Overview.....................................................................................................................................1936 Removing shafts..........................................................................................................................1937 Disassembling output shaft................................................................................................................1938 Overview.....................................................................................................................................1938 Disassembling shaft .....................................................................................................................1939 Dismantling input shaft......................................................................................................................1939 Overview.....................................................................................................................................1939 Disassembling shaft .....................................................................................................................1941 34 35 37 Assembling transmission GT2...................................................................................................1942 Tools..................................................................................................................................................1942 Assembling input shaft......................................................................................................................1942 Assembling shafts ........................................................................................................................1943 Tightening torques .......................................................................................................................1944 Assembling input shaft......................................................................................................................1944 Assembling shaft.........................................................................................................................1944 Installing input and output shaft........................................................................................................1944 Installing shafts ............................................................................................................................1944 Tightening torques .......................................................................................................................1947 Fitting gear housing...........................................................................................................................1948 Fitting housing .............................................................................................................................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 45 46 19 Removing and installing front ABS lead (GT2)..........................................................................1952 Removing front ABS lead ..................................................................................................................1952 Installing front ABS lead...................................................................................................................1954 Tightening torques.............................................................................................................................1955 Tools..................................................................................................................................................1955 50 30 19 Removing and installing air guide GT2 ....................................................................................1956 Removing and installing air guide.....................................................................................................1956 55 90 19 Removing and installing rear lid GT2......................................................................................1958 Removing and installing rear lid........................................................................................................1958 55 90 37 Disassembling and assembling rear lid GT2............................................................................1961 Disassembling rear lid ........................................................................................................................1961 Assembling rear lid............................................................................................................................1964 Replace model logo.....................................................................................................................1966 Removing and installing rearlid wiring harness.......................................................................1966

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63 15 19 Removing and installing front spoiler GT2 ..............................................................................1969 Removing front spoiler......................................................................................................................1969 Installing front spoiler........................................................................................................................1971 63 15 37 Disassembling and assembling front spoiler GT2...................................................................1973 Disassembling front spoiler...............................................................................................................1973 Removing front spoiler ................................................................................................................1975 Installing front spoiler........................................................................................................................1976 Installing front spoiler.................................................................................................................1977 66 58 19 Removing and installing rear spoiler GT2...............................................................................1979 Removing rear spoiler........................................................................................................................1979 Installing rear spoiler.........................................................................................................................1981 Replacing rear spoiler fork..........................................................................................................1982 69 72 19 Removing and installing rollover bar GT2............................................................................1984 Removing rollover bar.....................................................................................................................1984 Installing the rollover bar................................................................................................................1987 Adjusting the rollover bar................................................................................................................1991 Assembly instructions for the rear trim, the floor covering and the closure caps.............................1991 72 01 19 Removing and installing bucket seat GT2 as of MY 2001...................................................1993 Removing bucket seat GT2 ................................................................................................................1993 Installing bucket seat GT2.................................................................................................................1995 Fitting sixpoint seat belt GT2................................................................................................1996 96 61 19 Removing and installing relay for main switch GT2 as of MY 2001..................................1998 Installing the main battery relay........................................................................................................1999 Installing inner EMERGENCY STOP switch...................................................................................2000 Removing the main battery relay.......................................................................................................2001 Removing the inner EMERGENCY STOP switch ............................................................................2002 Operating the main battery switch.....................................................................................................2003 Status A Road . Status B Racing track...........................................................................2003 Actuating inner EMERGENCY STOP switch............................................................................2004 Moving the EMERGENCY STOP switch to its starting position ...............................................2005 53 05 55 Replacing rear closing panel Carrera 4S ..................................................................................2006 Cutting out rear closing panel............................................................................................................2006 Inserting rear closing panel................................................................................................................2008 Tools and materials............................................................................................................................2010 53 69 19 Removing and installing rear wheel housing liners Carrera 4S .............................................2012 55 90 19 Removing and installing rear lid Carrera 4S...........................................................................2014 55 90 37 Disassembling and assembling rear lid Carrera 4S................................................................2016 Disassembling rear lid ........................................................................................................................2017 Assembling rear lid............................................................................................................................2019 lxi

einordnung

Table of Contents
55 90 37 Disassembling and assembling rear lid Carrera 4S Removing and installing additional brake light.................................................................................2022 Installing rubber covering Cabriolet...............................................................................................2023 Removing and installing reflector 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 rear lid hinges Carrera 4S...............................................................2027 19 58 19 Removing and installing coolant regulator ..................................................................................2030 Removal overview of the coolant regulator.......................................................................................2030 Installation overview of the coolant regulator...................................................................................2033

lxii

Information on handling of the GT2 scope.

This supplement represents the basic edition for the vehicle 911 GT2. The GT2 is 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 transmission" and should be updated there with a separate Table of Contents.

996840, 996841

Information on handling of the GT2 scope.

0 Technical data
Engine Engine design Engine cooling Engine lubrication Engine control Heating Fuel system 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 DIN 700 20 Filling capacities Performance data Climbing performance Specific power

0 Technical data

einordnung

top of page

Engine

Engine Engine type No. of cylinders Bore Stroke Cubic capacity Compression ratio Max. engine power as per 80/1269/EEC Net power as per SAE J1349 Engine

M96/70 6 100 (3.94) 76.4 (3.01) 3600 (219.7) 9.4 : 1 309 (420) 415

mm (in.) mm (in.) cm3 (cu.in.) kW (HP) HP 3

einordnung at engine speed Max. torque as per 80/1269/EEC Net torque as per SAE J1349 at engine speed Max. litre output Engine speed limitation by fuel cutoff at Idle speed Automatic transmission Engine weight as per DIN 70020 A, kg 6750 740 40 740 40 Manual transmission 260* (572.7) rpm rpm rpm Automatic transmission 253 (557.27) 6000 560 (57.08) 415 2700 to 4600 85.8 (116.6) HP/l rpm Nm (ftlb.) ftlb. rpm kW/l (HP/l) (115.3)

* including ZMS (doublemass flywheel) top of page

Engine design

Engine design Type Crankcase Cylinder housing Crankshaft Crankshaft bearings Connecting rods Conrod bearings Piston Cylinder Cylinder head Camshaft housing Valve guide Valve arrangement

Valve control Camshaft

6cylinder aluminium opposedcylinder engine, water cooled, biTurbo Vertically divided crankcase made from cast light alloy, separate cylinder housing Cast light alloy with wet light alloy bushings inserted, Nikasil coating Forged, supported by 8 bearings Plain bearings Forged Plain bearings Pressed light alloy Nikasil cylinder lining Light alloy Aluminium alloy Pressed in 2 inlet valves suspended in parallel V arrangement 2 exhaust valves suspended in parallel V arrangement Via flatbase tappets From the crankshaft via a gear wheel to the intermediate shaft, and from there to the exhaust and inlet camshafts via one double chain each. 4

Engine design

einordnung Camshaft adjustment Valve clearance Valve timing with 1 mm valve travel and zero clearance (kinetic clearance of the operating plunger taken into account, basic inlet camshaft setting early) Intake system Porsche VarioCam Plus with 30 adjustment Hydraulic valve clearance compensation Inlet opens at 10 before TDC Inlet closes at 20 after BDC Outlet opens at 41 before BDC Outlet closes at 9 before TDC Tunedintake system (plastic)

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Engine cooling

Engine 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 Type Oil cooling Oil filter Oil pressure at n = 5000 rpm Oil pressure indicator Oil consumption

Dry sump lubrication with separate canister Via oilwater heat exchanger On pressure side behind oil pump Approx. 6.5 bar at 90 C Oil pressure indicator light plus instrument Max. 1.0l/1000km

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Engine control

Engine control Engine control module Ignition Firing order

Bosch ME 7.8 DME, individual spark coils, knock control 162435

Engine cooling

einordnung Ignition timing control Spark plugs Electrode gap mm (in) Egas USA version Boost pressure control Via DME (ECM) Bosch FR 5 LOC Beru 14FR 5 LDU 1.6 0.2 (0.06 0.008) Electronic throttle actuator control via DME ME 7.8 OnBoard Diagnosis II Absolutely pressureguided turbocharger control

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Heating

Heating Via water heat exchanger, closed loopcontrolled on air side

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Fuel system

Fuel system Injection Fuel supply Fuel quality (RON)

ME 7.8 (DigitaleMotorElectronic engine control module ECM) Injection valves controlled sequentially 1 electrical internal gear pump with 2 additional sucking jet pumps 98 unleaded

top of page

Electrical system

Electrical system Radio interference suppression Rated voltage Battery capacity Starter Rated generator output

ECER 10 and 95/54/EC 12 80/380 1.7 1680 (threephase generator)

V Ah/A kW W

top of page Engine control 6

einordnung

Exhaust system

Exhaust system 2pipe, 3way catalytic converter exhaust system, rear mufflers

top of page

Emission control

Emission control EURO III

USA LEV

Stereo oxygen sensor closedloop control and 3way catalytic converter system, each with a 2stage catalytic converter on left+right, secondary air system, Europe OBD Stereo oxygen sensor closedloop control and 3way catalytic converter system, each with a 2stage catalytic converter on left+right, secondary air system, OBD II + ORVR

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Transmission

Transmission Engine and transmission bolted together to form a power unit. Rear axle drive via doublejointed drive shafts, front axle drive via cardan shaft, front axle transmission and doublejointed drive shafts.

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Clutch

Clutch Manual transmission Contact plate Clutch plate Automatic transmission Converter Movingoff ratio Stall speed Exhaust system

Singleplate dry clutch, hydraulic actuation with hydraulic support, doublemass flywheel GGG 60 240 270 (10.64) 1.92 2600 mm (in) rpm 7

einordnung

top of page

Transmission

Transmission Manual transmission TOP G 96.50 Number of gears, forward/reverse Internal designation, transmission ratios (i) 1st gear 2ndgear 3rd gear 4th gear 5th gear 6th gear Reverse gear Final drive Final drive ration rear axle (i) front axle Transmission weight (dry) kg (lbs) Transmission weight wet and ready for installation kg (lbs) Front axle transmission weight with longneck pipe (wet) kg (lbs) 6/1 Tiptronic TOP A 96.50 Z front axle transmission TOP Z 96/00

5/2

3.82 2.05 1.41 1.12 0.92 0.75 2.86 Bevel gear wheel 3.44

3.59 2.19 1.41 1.00 0.83 1.93/3.16

2.889 2.883 116.5 (256.82) asdelivered condition dry

3.44

68.6

72

125.2 (272.47) with converter, with oil, with cooler (asdelivered condition)

23.0

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Clutch

einordnung

Body designs

Body designs Lightweight, galvanised allsteel integral bodyframe, partially HSLA, fullsize airbag for driver and passenger, side airbag. No. of seats = 2+2

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Running gear

Running gear Front axle

Spring strut axle

Springs

Spring wire diameter Coil diameter No. of turns Stabilizer diameter Vibration damper Rear axle Wheel suspension Springs Spring constant Spring wire diameter Coil diameter No. of turns Stabilizer diameter Vibration damper Steering Steering wheel diameter Steering ratio Turning circle diameter Body designs

Spring constant 12.6 to 14.0 113.2 to 186.5 (3.6 to 7.35) 4.05 23.6 x 3.5 mm (in) tubetype stabilizer Doubleacting hydraulic twintube gasfilled vibration damper Multilink axle Wheels individually guided by 5 control arms Cylindrical coil spring per wheel, with coaxial vibration damper inside spring 60 N/mm 13.21/13.35 mm (in) 115.0 mm (in) 6.75/7.0 21.7 x 3.0 mm (in) tubetype stabilizer Doubleacting hydraulic singletube gasfilled vibration damper 380 (14.77) 16.9 :1 16.9 : 1 10.6 (34.8) mm (in) Lefthand drive Righthand drive m (ft)

Wheels individually suspended by control arms with trailing arms and spring struts (McPherson design, optimised by Porsche) One truncated cone spring per wheel, with vibration damper inside spring 33 N/mm mm (in) mm (in)

einordnung Track circle diameter 10.2 (33.5) m (ft) Steering wheel 2.98 Lefthand drive revolutions from lock to lock 2.98 Righthand drive Power steering pump Driven via poly Vbelt Ratio i = 1 : 0.95

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Brakes

Brakes Operating brake

Foot operated, hydraulicmechanical boost, dualcircuit brake system, 4piston Al monobloc brake calipers at FA and RA, distributed per axle, internally ventilated brake discs at front and rear axles. 3.85 25.4 (1.00) mm (in) 18/18 (0.71/0.71) mm (in) front 330 (13.00) mm (in) rear 330 (13.00) front 134 (5.28) mm (in) rear 136 (5.36) front 34 (1.34) mm (in) rear 28 (1.10) front 157 (24.34) cm2 (sq.in) rear 127 (19.69) front 36 (1.42) and 44 (1.73) mm (in) rear 28 (1.10) and 30 (1.18) Drumtype parking brake 180 (7.092) mm (in) 25 (0.985) mm (in) 85 (13.08) cm2 (sq.in) Standard Porsche Stability Management (PSM) with ABS, Traction Control (TC), ABD, MSR (engine drag torque control), FZR (vehicle regulator) and EBV (electronic brake distributor). Passive switching possibility for TC, FZR and MSR.

Vacuum brake booster (boost factor) Brake master cylinder Brake master cylinder stroke Brake discs Effective brake disc Brake disc thickness Effective total brake pad area per wheel Piston in brake caliper Parking brake Brake drum Brake shoe width Lining area per wheel Running gear control systems

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Running gear

10

einordnung

Wheels and tyres

Wheels and tyres Summer tyres Tyre size, front on wheel Tyre size, rear on wheel Winter tyres ** Tyre size, front on wheel Tyre size, rear on wheel

225/40 ZR 18 8 J x 18 295/30 ZR 18 11 J x 18 225/40 R 18 88H M + S 8 J x 18 265/35 R 18 93H M + S 10 J x 18

RO (mm) 50* 45* RO (mm) 50 47**

* only if specified make is fitted ** M + S tyres with higher load rating and/or higher speed symbols 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 Wheel Tyre pressure front rear Collapsible wheel

165/70 * R16 92P Vredestein Space Master 5.5 J x 16 rim offset 10 summer winter 2.5 2.5 3.0 3.0 2.5

bar bar bar

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Wheel alignment

Wheel alignment Front axle at DIN empty weight Toein (total) Camber USA RoW

+ 5 min. 5 min. (max. difference left to right: 5 min.) 0 degrees 15 min. 30 min. 15 min. (max. difference left to right: 20 min.) 11

Wheels and tyres

einordnung 8 degrees 30 min. (max. difference left to right: 40 min.) Toedifference angle at 20 degrees lock RoW 2 degrees 20 min. 30 min. USA 1 degree 20 min. 30 min. Rear axle at DIN empty weight Toein (per wheel) Camber Caster

+ 10 min. 5 min. (max. difference left to right: 10 min.) 1 degree 25 min. 15 min. (max. difference left to right: 15 min.)

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Dimensions

Dimensions Length 4435 (174.74) Width 1830 (72.0) Height 1295 (51.02) at DIN empty weight Wheel base 2350 (92.59) Track widths 18 inch front 1465 (57.72) rear 1522 (59.97) Ground clearance 90* (3.55) for USA 110* (4.33) at permissible total weight 55 (2.17) Ramp angle 12.5* for USA 14.0* Overhang angle, front 10.0* for USA 12.0* Overhang angle, rear 13.0* for USA 13.5* * Design position according to Porsche definition in acc. with PN 230

mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in)

degrees degrees degrees degrees degrees degrees

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Weights according to DIN 700 20

Weights according to DIN 700 20 Wheel alignment 12

einordnung Coup manual transmission Coup Tiptronic

Empty weights according to equipment kg (lbs) front 605 (1333.7) 605 (1333.7) rear 935 (2061.2) 980 (2160.4) entire Coup* 1540 (3394.9) 1585 (2494.1) * for EU homologation plus 75 kg driver's share (35 kg at front axle, 40 kg at rear axle) Permissible axle load Coup, front 825 (1818.71) 825 (1708.49) rear 1180 (2601.3) 1180 (2601.3) Max. gross weight 1885 (4155.48) 1930 (4254.69) Max. trailer load Braked none none Unbraked none none Permissible towed weight none none Permissible drawbar load none none Permissible roof load, kg (lbs.) with Original Porsche Roof Transport System 75 (165) 75 (165)

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Filling capacities
Note Measurement of the engine oil level by instrument or oil dipstick! The Driver's Manual is definitive!

Filling capacities Engine specification

Approved: Europe:

USA, RoW:

Engine oil quantity

Approx. 12.5 (2.71) change quantity 8.5 (1.84) with filter change 8.75 (1.90)

According to ACEA Specification A496 and special Porsche requirements (refer to Techn. Info. notice about engine oils) According to API SG und SHn Specification and special Porsche requirements (refer to Techn. Info. notice about engine oils) l (Imp. gal.)

Weights according to DIN 700 20

13

einordnung Manual transmission with differential Automatic transmission with torque converter Differential Specification for transmission oil (first filling) 3.8 (0.82) Approx. 9,0 (1,95) 1.2 (0.26) Manual transmission SAE 75 W90 Mobilube PTX Specification for differential transmission oil, Tiptronic (first filling) Fuel tank RoW refill volume (nominal volume) USA refill volume (nominal volume) Coolant Brake fluid reservoir Tank for windscreen washer and headlight cleaning system Power steering l (Imp. gal.) l (Imp. gal.) l (Imp. gal.) Tiptronic Shell ATF 3403M115 SAE 85 W 90 or BP Olex GO 4927 Reserve 12 (2.6) Approx. 64 (13.87) Approx. 63 (13.65) 28 (6.07) l (Imp. gal.) Approx. 0.63 (0.136) Approx. 2.5/6.5 (0.54/1.41) 2.14 Pentosin CHF 11S l (Imp. gal.) l (Imp. gal.) l (Imp. gal.) 29 (6.28) l (Imp. gal.) l (Imp. gal.) l (Imp. gal.) l

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Performance data

Performance data Top speed Acceleration Acceleration Acceleration Kilometre from standing start 1/4 mile from standing start Elasticity 80 120 km/h 100 200 km/h Manual transmission 305 (189.4) 4.2 s 9.2 s 14.2 s 22.4 s Tiptronic 298 (185.1) 4.9 s 10.6 s 16.74 s 23.9 s km/h mph 0 100 km/h 0 160 km/h 0 200 km/h

5.0 s 11.9 s

5th gear 5th gear

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Filling capacities

14

einordnung

Climbing performance

Climbing performance 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Manual transmission 89.3 89.5 50.9 37.4 29.0 21.9 Tiptronic 79.3 70.4 38.1 24.3 17.9 % % % % % %

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Specific power

Specific power Manual transmission 4.98 3.66 3.71 Tiptronic 5.12 3.77 3.81 kg/kW kg/HP kg/HP

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Climbing performance

15

0 Entire vehicle
Lifting the vehicle top of page

General

Lifting the vehicle

CAUTION Danger of material damage if the vehicle is raised incorrectly or if the vehicle is driven incorrectly onto the lifting platform! Lift the vehicle only at the takeup 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 lift and the vehicle! In order to avoid damage to the side members and side member panels, the mounting plates of the platform lift must be raised!

front

rear

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

0 Entire vehicle

General

16

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

einordnung

Engine

Engine Engine type No. of cylinders Bore Stroke Cubic capacity Compression ratio Max. engine power as per 80/1269/EEC Net power as per SAE J1349 at engine speed Max. torque as per 80/1269/EEC Net torque as per SAE J1349 at engine speed Max. litre output Engine speed limitation by fuel cutoff at Idle speed Automatic transmission Engine weight as per DIN 70020 A, kg

M96/70 6 100 (3.94) 76.4 (3.01) 3600 (219.7) 9.4 : 1 309 (420) 415 6000 560 (57.08) 415 2700 to 4600 85.8 (116.6) HP/l

mm (in.) mm (in.) cm3 (cu.in.) kW (HP) HP rpm Nm (ftlb.) ftlb. rpm kW/l (HP/l) (115.3)

6750 740 40 740 40 Manual transmission 260* (572.7)

rpm rpm rpm Automatic transmission 253 (557.27)

* including ZMS (doublemass flywheel) top of page

Engine design

Engine design Type Crankcase Cylinder housing Crankshaft Crankshaft bearings Engine

6cylinder aluminium opposedcylinder engine, water cooled, biTurbo Vertically divided crankcase made from cast light alloy, separate cylinder housing Cast light alloy with wet light alloy bushings inserted, Nikasil coating Forged, supported by 8 bearings Plain bearings 18

einordnung Connecting rods Conrod bearings Piston Cylinder Cylinder head Camshaft housing Valve guide Valve arrangement Forged Plain bearings Pressed light alloy Nikasil cylinder lining Light alloy Nonmetallic Pressed in 2 inlet valves suspended in parallel V arrangement 2 exhaust valves suspended in parallel V arrangement Via flatbase tappets From the crankshaft via a gear wheel to the intermediate shaft, and from there to the exhaust and inlet camshafts via one double chain each. Porsche VarioCam Plus with 30 adjustment Hydraulic valve clearance compensation

Valve control Camshaft

Camshaft adjustment Valve clearance Valve timing with 1 mm valve travel and zero clearance Inlet opens at 10 before TDC (kinetic clearance of the operating plunger taken Inlet closes at 20 after BDC into account, basic inlet camshaft setting early) Outlet opens at 41 before BDC Outlet closes at 9 before TDC Intake system Tunedintake system (plastic)

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Engine cooling

Engine cooling Water cooling; 3 radiators ahead of the front wheels. (Additional radiator for Tiptronic vehicles) Two electric fans, controlled in three stages

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Engine lubrication

Engine lubrication Type Oil cooling Oil filter

Dry sump lubrication with separate canister Via oilwater heat exchanger On pressure side behind oil pump

Engine design

19

einordnung Oil pressure at n = 5000 rpm Oil pressure indicator Oil consumption Approx. 6.5 bar at 90 C Oil pressure indicator light plus instrument Max. 1.0l/1000km

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Engine control

Engine control Engine control module Ignition Firing order Ignition timing control Spark plugs Electrode gap mm (in) Egas USA version Boost pressure control

Bosch ME 7.8 DME, individual spark coils, knock control 162435 Via DME (ECM) Bosch FR 5 LOC Beru 14FR 5 LDU 1.6 0.2 (0.06 0.008) Electronic throttle actuator control via DME ME 7.8 OnBoard Diagnosis II Absolutely pressureguided turbocharger control

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Engine lubrication

20

0 Transmission
6speed manual transmission G 96.50 Front wheel drive Z 96.00 top of page

6speed manual transmission G 96.50

Type G 96.50

Code letter

Equipment 6speed

Installed in 911 Turbo (996)

Model year 2001

General data Transmission ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Reverse gear Final drive Transmission ratio, final drive Filling capacity for new filling Change quantity

Manual transmission G 96.50 Z1 : Z2 = Z2 : Z1 11 : 42 = 3.82 21 : 43 = 2.05 27 : 38 = 1.41 34 : 38 = 1.12 37 : 34 = 0.92 40 : 30 = 0.75 14 : 40 = 2.86 Hypoid bevel gear drive with 10 mm offset 9 : 31 = 3.44 3.8 l 3.0 l

0 Transmission

21

einordnung top of page

Front wheel drive Z 96.00

Type Z 96.00

Code letter

Equipment

Installed in 911 Turbo (996) worldwide

Model year 2001

General data Transmission ratio, final drive (Z2 : Z1 = i) Final drive Filling capacity

Frontaxle final drive Z 96.00 31 : 9 = 3.44 Bevel gear drive without hypoid offset approx. 1.5 l

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

6speed manual transmission G 96.50

22

0 Body
Body of highstrength steel 1 Body of highstrength steel 2 Water drainage plan Coup Refrigerant circuit Component arrangement, Airbag System B05 top of page

Body of highstrength steel 1

The indicated body parts are made by welding together plates of differing thicknesses and characteristics and then deepdrawing these parts. In their crash behaviour, these body parts are characterised by their high energy absorption. 0 Body 23

einordnung top of page

Body of highstrength steel 2

Note The use of highstrength steels for the body has an effect on body repairs. For this reason, only Original Porsche parts must be used for repair 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 indicated body parts attain their final strength only under the temperature effects of the production stage of cathodic immersion painting and drying.

Body of highstrength steel 1

24

einordnung top of page

Water drainage plan

Coup

1 2 3 4 5

Water drainage: Rear of sliding roof Water drainage: Front of sliding roof Water drainage: Evaporator of heating and airconditioning system Water drainage: Tank tray Water drainage: Radiator tank

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Body of highstrength steel 2

25

einordnung

Refrigerant circuit

1 2 3 4 5

Compressor Condenser Fluid tank Expansion valve Evaporator

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Component arrangement, Airbag System B05

Refrigerant circuit

26

einordnung

1 2 3 4 5 6 7 8 9

Triggering unit Passenger's airbag unit Warning light Driver's airbag unit Side airbag Contact unit Sideairbag sensor Belt buckle, driver/passenger Plug connection, child restraint system

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Component arrangement, Airbag System B05

27

0 Electrics
Fuse assignments top of page

Fuse assignments

A to E F G H No. Row A 1 2 3 4 5 6 7 8 9 10 Row B 1

Fuses (rows A...E or 1...10) Switch for retractable spoiler Replacement fuses Gripper Load Amperage rating 15 15 7.5 7.5 15 25 25 7.5 15 15 15 28

High beam headlight, right High beam headlight, left Side lights, right Side lights, left Number plate light, instrument lighting Seat heating Fog lights, rear fog light Number plate light for Canada Dipped beam headlight, right Dipped beam headlight, left

0 Electrics

einordnung Instrument cluster, Tiptronic, PSM/ASR button, diagnosis, convertibletop drive Hazard warning light Horn Enginecompartment fan Reversing lights, convertibletop drive control module, mirror and mirror memory Direction indicator light, power window touchcontrol enabling Brake lights, cruise control Control modules for central locking system, alarm system, DME, Tiptronic Control module for ABS/ASR/PSM, Traction Control Instrument cluster, diagnosis, headlight beam adjustment DME relay Ignition relay, oxygen sensors Control module for central locking system, alarm system, power windows Fuel pump relay Enginecompartment fan (optional) Windshield wipers Terminal X, control wiring Radiator fan 2 Headlight washer Radiator fan 1

2 3 4 5 6 7 8 9 10 Row C 1 2 3 4 5 6 7 8 9 10

15 25 15 7.5 15 15 15 15 15 25 30 15 25 5 25 5 40 25 40

Note If the power windows should fail, check fuse C3 (15 A) in addition to fuse D1 (30 A).

No.

Load

Amperage rating 30 30 30 30 15 30 15 15 15 7,5 29

Row D 1 Power windows 2 Door mirror, rear window heater 3 Convertibletop drive, sliding roof 4 Rear power windows, cabriolet 5 Cigarette lighter 6 Heating relay 7 Retractable spoiler 8 Radio 9 Sound package 10 Slot for additional equipment Caution max. 5A! Fuse assignments

einordnung Row E 1 Terminal 86 S, instrument cluster, radio, daytime driving light, control modules for central locking, alarm system, information system, rollover sensor 2 Control module for seat memory 3 Control module memory for seat adjustment, left 4 Control module memory for seat adjustment, right 5 Information system 6 Terminal 30, telephone, navigation control module 7 Air conditioning 8 Terminal 15, telephone, information system 9 PSM 10 PSM

7,5 7,5 30 30 7,5 7,5 7,5 7,5 25 15

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Fuse assignments

30

0 Power supply
Work instructions after disconnecting the battery Control module memories Supply voltage fault entry Test drive after connecting the battery 2470 DME control module 3730 Tiptronic 6452 Power windows 90 25 Instrument cluster 9030 Clock 9023 Fuel level display 9120 Radio 9110 PCM top of page

Work instructions after disconnecting the battery

Note In order to avoid triggering the alarm siren (installed on right next to the battery) of vehicles with M 536, the battery must be disconnected with 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 engine! Whenever possible, use jump leads with overvoltage protection! Always disconnect both battery terminals before carrying out welding work on the vehicle! Wiring harness plugs of control modules or other electronic components must be connected or disconnected with the ignition off. Exception: vehicles with the additional equipment M 536 (alarm siren with tilt sensor)!

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Control module memories

Problem Values and faults stored in the control modules can be deleted if the battery is disconnected or completely discharged.

Remedy If possible, all fault memories should be checked and, if necessary, printed out before the battery is disconnected. 31

0 Power supply

einordnung

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Supply voltage fault entry

Problem The entry "supply voltage" could be stored in various control modules if the battery has been completely discharged.

Remedy Delete the "supply voltage" entry from the control modules in question.

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Test drive after connecting the battery

Note The fault memories of all vehicle control modules should be read out again after the test drive!

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2470 DME control module

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 the battery is connected. After disconnection of the power supply, the idle speed might With the DME ME 7.2, it is change or fluctuate briefly until the idle speed positioner (M necessary to carry out a learning 5.2) or the throttle adjusting unit (ME 7.2) is readapted. and adaptation routine as The mixture adaptation is also lost. described below: 1. Switch the ignition on for 1 minute without starting the engine. Do not actuate accelerator pedal. 2. Switch off ignition for at least 10 seconds. This completes the adaptation of the throttle adjusting unit.

Control module memories

32

einordnung

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3730 Tiptronic

Problem Remedy The stored pressure adaptation values are lost if the power Carry out a test drive and drive the supply to terminal 30 is interrupted. This can result in poor vehicle with different loads and at shifting quality and rough shift operations during the different speeds so that all shift adaptation phase. functions (manual and automatic programme) are executed at least once. This readapts the shifting pressures of the system and thereby reestablishes smooth shifting.

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6452 Power windows

Problem Remedy The limit positions of the power windows are deleted from Manually close each power window as the control module when the battery is disconnected and far as it will go, then press the rocker connected. switch for closing the window again. The limit position of the respective power window is now stored in the control module again.

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90 25 Instrument 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 disconnected!

Problem 2470 DME control module

Remedy 33

einordnung Depending on the software version, the clock is set to 12:00 a.m. or 1:00 a.m. when the power supply is disconnected. Enter the current time again.

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9023 Fuel level display

Problem If the power supply is interrupted by a discharged or disconnected battery with the tank containing less than 19 l, the calculated value for the range on remaining fuel in the instrument cluster will be incorrect or deleted. If the tank contains less than 10 l, it is possible that the fuel level warning light is no longer activated. 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.

Remedy Refill at least 19 l of fuel; then the fuel level sensor is in operating range and its display precision is guaranteed.

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9120 Radio

Problem Remedy The radio reverts to the Code function when the battery 1. Input the radio code. is disconnected and is thus no longer ready for operation. 2. If the code card is unavailable, the radio code can also be read from the DME control module (under "Vehicle data"). 3. This code is also available from the Porsche IPAS.

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9110 PCM

Problem

Remedy 1.

9030 Clock

34

einordnung The PCM reverts to the Code input function when the battery is disconnected and is thus no longer ready for operation. When the power supply is disconnected, the builtin GPS receiver loses the socalled almanac containing the satellite orbital paths. The date and time are deleted when the battery is disconnected. Radio stations stored by the customer are no longer displayed. If the telephone card was inserted and the telephone was ready for operation, the telephone is subsequently disabled. Input the PCM code. If the code card is unavailable, the PCM code can also be read from the 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 are also adopted once the GPS almanac has been loaded; it may be necessary to change over to summer time (daylightsaving time). This time is transferred to the instrument cluster. If the time is then manually changed by means of the instrument cluster, this time is adopted by the PCM and synchronised with GPS time. 5. The stored stations are displayed again when station buttons 1 to 6 are pressed. 6. 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

9110 PCM

35

01 General maintenance: Test drive

Note Note The following test items are included in the test drive. Checking footbrake operation and actuation travel. Actuating clutch, checking operation. Actuating 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 checking operation. Checking operation of heating adjustment when engine is warm. Checking operation of airconditioning system when the engine is running. Checking operation of the instruments.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

01 General maintenance: Test drive

36

01 Diagnostic system: Read out fault memory and activate systems

Activating systems Read out fault memory Load Navigation top of page

Activating systems
Note The work procedure is menuprompted, the Tester instructions have highest priority, further actuation is specified using the arrow symbols e.g., >> .

1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Press >> to continue. 2. Select Special functions menu 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 over . 5. Observe Tester instructions and code >> using F8 . 6. Enter the required chassis number >> . 7. Pay attention to the instructions from the Tester All functions carried out and PCM/CDR was activated . >> . Continue with => Read out fault memory. top of page

Read out fault memory

Porsche System Tester connected to vehicle and System Tester started. Ignition switched on. 1. Select vehicle type. >> Note

01 Diagnostic system: Read out fault memory and activate systems

37

einordnung All control modules are read out automatically one after the other. 2. Control modules showing an error have an asterisk in front of their designation >> *DME. 3. Select these control modules, select Read out fault memory menu. 4. The fault memory can now be erased in the Erase fault memory menu. 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 Diagnosis Manual .

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Load Navigation
Note Only vehicles with PCM. 1. Insert Navigation CD in PCM and switch on PCM. 2. Navigation CD will be loaded. 3. Disconnect Tester on vehicle.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Read out fault memory

38

01 Battery: checking the charge state

Tools Checking charge state with battery tester top of page

Tools

Item

Designation Battery rapidstart charger

Source see Workshop Equipment Manual, Chapter 3

Remarks

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Checking charge state with battery tester

Note Follow the instructions for the Tester, topic: charge state/functional state. The tester must be connected directly to the battery. 1. Remove battery cover. 2. Connect the battery tester to the vehicle battery and check the charge state according to the operating instructions for the tester. Evaluation of test results and further procedures: Opencircuit voltage Charge state 12.7 12.5 V 100 80 % 12.5 12.2 V 80 50 % 12.2 11.6 V Below 11.6 V 50 10 % Below 10% Evaluation and procedure Charge state OK Charge state reduced, recharge battery and observe inactive period of 2 h after charging. 2, 2706 Battery Battery flat, recharge battery and observe inactive period of 2 h after charging. 2, 2706 Battery Battery totally discharged, replace battery

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

01 Battery: checking the charge state

39

01 Windscreen wiper/washer system, headlight washer

Caution Mix ratio of fluids for windscreen washer system CAUTION Danger of material damage if headlights are cleaned incorrectly! Use only soapy water to clean the exterior lights and the plastic headlight lenses! Never use chemical cleaning agents! To avoid scratches, do not rub with dry or only damp cloths, paper towels or insectremoval sponges! Note The headlight washer nozzles are preset! It is not necessary to adjust them! Check the function, fluid levels and nozzle settings. top of page

Mix ratio of fluids for windscreen washer system

Fluid: Water Water/isopropanol

Water/ethanol

Mix ratio: Undiluted 1:1 2:1 3:1 1:1 2:1 3:1

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

01 Windscreen wiper/washer system, headlight washer

40

01 Checking the function of the vehicle's lights and the headlight setting
Checking the adjustment of the headlights Adjusting the main headlights Adjusting the main headlights, USA version Fog light adjustment Vehicle lights: Switch on the ignition, and switch through all exterior and interior light functions in turn. Check the function of the exterior lighting with the help of a second person. Horn: Switch on ignition, press actuation for horn on steering wheel and check the sound of the horn. Clock Check current time, set if necessary. In the instrument cluster, turn the right setup button with the Clock symbol to the left/right. This sets the hours. When this setup 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 present) and if necessary, set the time in the PCM as well.

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Checking the adjustment of the headlights

Note Set the headlight adjustment unit to 10 cm/10 m (1%)! With this alignment, preference must be given to the central zone around the salient point of the light/dark limit! First, make the vertical adjustment of the dipped beam headlights. 1. To do this, line up the light/dark borderline running upwards at an angle on the righthand side with the dotted 15 line of the adjustment unit. Next, perform the horizontal adjustment of the dipped beam headlights.

01 Checking the function of the vehicle's lights and the headlight setting

41

einordnung

2. To do this, line up the left, horizontal section of the light/dark limit (when driving on the right) with the dotted horizontal line of the adjustment unit. Note The distance between the headlights and the adjustment unit should be as small as possible! It should not exceed 30 cm, because if the distance is greater, it is no longer possible to define the formation of the light/dark limit in the adjustment unit clearly! 3. Secure the plugs after making the adjustment. 4. In the case of Xenon headlights, 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. Open the luggage compartment lid. 2. Remove the luggage compartment mat on the wheel housing wall.

3. Open the cover for 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 (headlight beam adjustment)! Use a standard 5 mm ballhead screwdriver to make the headlight adjustment (free blade length 150 mm)!

Checking the adjustment of the headlights

42

einordnung Only the lower screw may be turned for height adjustment; for lateral adjustment the upper and lower screws must be turned in the same direction and for the same number of rotations!

5. Make the adjustment 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. A Lateral adjustment B Height and lateral adjustment C Fog light adjustment top of page

Adjusting the main headlights, USA version

Note A new adjustment may only be made in the case of accident repairs or replacement of the main headlights! Vertical and horizontal adjustment must be carried out with a headlight adjustment unit. top of page

Fog light adjustment

Note The vehicle must be on a horizontal surface!

Adjusting the main headlights

43

einordnung Make the adjustment 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 adjustment Note Switchedon headlights must not be covered by a front apron or film!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Fog light adjustment

44

01 Checking the function of electrical equipment, as well as the indicator and warning lights
Turn ignition key and check function of warning and indicator lights (visual inspection). Actuate power windows and check operation. Check that rear window heater is in working order. Adjust heater blower 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 orientation lights. Actuate central locking and check operation. Operate cigarette lighter and check that it is in working order.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

01 Checking the function of electrical equipment, as well as the indicator and warning lights

45

01 Alarm system: checking operation of indicators

Vehicle must be unlocked and the sales check step Diagnostic system: systems activated and fault memory read out must be carried out. 1. Lock vehicle with the remote control. Shortly after locking, the alarm system horn should not issue a warning tone. If a warning tone is issued, check all doors, as well as the convertible top, 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 double flashing signal, and after 10 seconds have passed, a single flashing signal. 3. If a flashing signal is not shown, or if the double flashing signal continues, connect the System Tester and read out the fault memory. 0, 96 Alarm system diagnosis manual

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

01 Alarm system: checking operation of indicators

46

01 Activating/deactivating the parking aid

Note General Activating the parking aid without PST 2 Deactivating the parking aid without PST 2 Activating the parking aid with PST 2 Selecting door mirror to be lowered, left/right Adjusting the lowering angle for the passenger door mirror Deactivating the parking aid with PST 2 Note This function is only available in vehicles with seat memory! Activation/deactivation can take place with/without PST 2!

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General
The automatic lowering of the passenger door mirror aids the driver during parking manoeuvres. 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 reverse gear still engaged, the door mirror returns to its stored position. The following settings can be selected from the menu and encoded using the PST 2: Parking aid (activated or deactivated) Parking aid with door mirror (right or left) Lowering

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Activating the parking aid without PST 2

1. Switch ignition on. 2. Engage reverse gear. 3. Adjust both door mirrors to desired positions. 4. Adjust seat to desired position. 5. Save seat position. Press M and corresponding seat memory position ( 1 , 2 or 3 ) simultaneously. Note

01 Activating/deactivating the parking aid

47

einordnung The parking aid is activated for the respective seat position saved! Activation of the parking aid must be carried out individually for every seat position!

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Deactivating the parking aid without PST 2

1. Switch ignition on. 2. Disengage reverse gear if necessary. 3. Adjust both door mirrors to desired positions. 4. Adjust seat to desired position. 5. Save seat position. Press M and corresponding seat memory position ( 1 , 2 or 3 ) simultaneously. Note The parking aid is now deactivated for the respective seat position!

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Activating the parking aid with PST 2

1. Connect the PST2 with the ignition off, then switch the ignition on. 2. Switch on the PST2 and wait for the startup screen. 3. Press the >> key to go to the next level. 4. Select the vehicle type 911 (996) Turbo in the lefthand window using the v key. 5. Press the > key to activate the righthand window. 6. With the v key, select 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 Parking aid for position 1 or Parking aid for position 2 or Parking aid for position 3 . 9. Press the >> key to alter the coding. 10. Select the menu item activated using the v / ^ key. 11. Press key F8 (coding) Note The parking aid is now activated for the respective seat position!

Activating the parking aid without PST 2

48

einordnung top of page

Selecting door mirror to be lowered, left/right

Note The door mirror (left/right) can be adjusted with the PST 2 only! 1. Connect the PST2 with the ignition off, then switch the ignition on. 2. Switch on the PST2 and wait for the startup screen. 3. Press the >> key to go to the next level. 4. Select the vehicle type 911Turbo (996) in the lefthand window using the v key. 5. Press the > key to activate the righthand window. 6. With the v / ^ key, select the Seat memory control module and press the >> key to go to the next level. 7. Select the menu item Parking aid on door mirror using the ^ / ^ key. 8. Press the >> key to go to the next level. 9. Select the desired door mirror right or left using the v / ^ key. 10. Press key F8 (coding) Note The selected door mirror is now activated!

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Adjusting the lowering angle for the passenger door mirror

Note The lowering angle of the passenger door mirror can be adjusted with the PST 2 only! 1. Connect the PST2 with the ignition off, then switch the ignition on. 2. Switch on the PST2 and wait for the startup screen. 3. Press the >> key to go to the next level. 4. Select the vehicle type 911Turbo (996) in the lefthand window using the v key. 5. Press the > key to activate the righthand window. 6. With the v key, select 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. Select the menu item Lowering using the v / ^ key. 9. Press the >> key to alter the coding. 10. Adjust the lowering angle using the v / ^ key. 11. Press key F8 (coding) Note

Activating the parking aid with PST 2

49

einordnung The lowering angle is now set!

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Deactivating the parking aid with PST 2

1. Connect the PST2 with the ignition off, then switch the ignition on. 2. Switch on the PST2 and wait for the startup screen. 3. Press the >> key to go to the next level. 4. Select the vehicle type 911Turbo (996) in the lefthand window using the v key. 5. Press the > key to activate the righthand window. 6. With the v key, select 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 Parking aid for position 1 or Parking aid for position 2 or Parking aid for position 3 . 9. Press the >> key to alter the coding. 10. Select the menu item Deactivated using the v / ^ key. 11. Press key F8 (coding) Note The parking aid is now deactivated for the respective seat position!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Adjusting the lowering angle for the passenger door mirror

50

01 Removing transport lock (spring strut locking devices) Turbo and GT2
General Removing spring strut locking devices top of page

General
Spring strut locking devices are installed on the front axle of the following new vehicles in order to protect the vehicle during transport (e.g. driving on and off when transported by lorry): Turbo RoW (new vehicles) Turbo USA (new vehicles) 911 GT2 (new vehicles) This increases the ground clearance of the vehicle. Tests have demonstrated that spring strut locking devices are not necessary at the rear axle. WARNING Danger of injury and damage to property if spring strut locking devices 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 devices must be removed before a test drive and before the vehicle is handed over to the customer! Note Send the removed spring strut locking devices to the Porsche Warranty Test Office in Ludwigsburg! Include the spring strut locking devices with the normal warranty goods consignment!

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Removing spring strut locking devices

Note The wheels need not be removed! 1. Lift the vehicle (wheels at the front axle must be free). 2. Remove spring strut locking devices from all spring struts. To do this, pull spring strut locking devices off the springs. 01 Removing transport lock (spring strut locking devices) Turbo and GT2 51

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing spring strut locking devices

52

Technical Data
Engine Engine design Engine cooling Engine lubrication Engine control Fuel system Electrical system Exhaust system Emission control

GT2

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Technical Data

GT2

53

einordnung

Engine

Engine Engine type Bore Stroke Cubic capacity Compression ratio Max. engine power as per 80/1269/EEC at engine speed Max. torque at engine speed Max. litre output Engine speed limitation by fuel cutoff at Idle speed Engine weight as per DIN 70020 A

mm (in.) mm (in.) cm (cu. in.) kW rpm Nm (ftlb.) rpm kW/l, HP/l rpm rpm kg

M96/70 S 100 (3.94) 76.4 (3.01) 3600 (219.7) 9.4:1 340 5700 620 (63.20) 3500 4500 94.44 6750 740 40 260

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Engine design

Type Crankcase Cylinder housing Crankshaft Crankshaft bearings Conrod bearings Connecting rods Cylinder Cylinder head Camshaft housing Valve guide Valve arrangement Valve control Camshaft

6cylinder aluminium opposedcylinder engine, water cooled, biTurbo Vertically divided crankcase made from cast light alloy, separate cylinder housing Cast light alloy with wet light alloy bushings inserted, Nikasil coating Forged, supported by 8 bearings Plain bearings Plain bearings Forged Nikasil cylinder lining Light alloy Aluminium alloy Pressed in 2 inlet valves suspended in parallel V arrangement 2 exhaust valves suspended in parallel V arrangement Via flatbase tappets From the crankshaft via a gear wheel to the intermediate shaft, and from there to the exhaust and inlet camshafts via one double chain each. Inlet opens 10 before TDC 54

Engine

einordnung Timing with 1 mm valve travel Inlet closes 20 after BDC Outlet opens 41 before BDC Outlet closes 9 before TDC Tunedintake system

Intake system

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Engine cooling

Engine cooling

Water cooling; 3 radiators ahead of the front wheels. Two electric fans, controlled in three stages

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Engine lubrication

Type Oil cooling Oil pressure at n=5000 rpm, T=90C Oil pressure indicator Oil consumption

Dry sump lubrication with separate oil container Via oilwater heat exchanger on pressure side behind oil pump Approx. 6.5 bar Oil pressure indicator lamp plus instrument Approx. 1.0 l/1000 km

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Engine control

Engine control module Ignition Firing order Spark plugs Electrode gap Egas Worldwide Boost pressure control

Bosch ME 7.8 DME, individual spark coils, knock control 162435 Bosch FR 5 LOC Beru 14FR 5 LDU 1.60.2 mm (0.060.008 in) Electronic throttle actuator control via DME ME 7.8 OnBoard Diagnosis Absolutely pressureguided turbocharger control

Engine design

55

einordnung top of page

Fuel system

Injection Fuel supply Fuel required

ME 7.8 (DigitaleMotorElectronic) Injection valves controlled sequentially 1 electrical internal gear pump with 2 additional sucking jet pumps RON 98 unleaded

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Electrical system

Radio interference suppression Rated voltage Battery capacity Starter Generator output

ECER 10 and 95/54/EC 12 V 80 Ah (380 A) 1.7 kW 1680 W

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Exhaust system

Exhaust system

2pipe, 3way catalytic converter exhaust system, rear mufflers

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Emission control

Europe/RoW Stereo oxygen sensor closedloop control and 3way catalytic converter system, each with a 2stage catalytic converter on left+right, secondary air system, Europe OBD emission control: EU3/D4 USA Stereo oxygen sensor closedloop control and 3way catalytic converter system, each with a 2stage catalytic converter on left+right, secondary air system, OBD II + ORVR emission control: LEV

996840, 996841

Engine control

56

Technical data
Engine Engine design Engine cooling Engine lubrication Engine control Fuel system Electrical system Exhaust system Emission control

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Technical data

57

einordnung

Engine

Engine Engine type Bore Stroke Cubic capacity Compression ratio Max. engine power as per 80/1269/EEC at engine speed Max. torque at engine speed Max. litre output Engine speed limitation by fuel cutoff at Idle speed Engine weight as per DIN 70020 A

mm (in.) mm (in.) cm (cu. in.) kW rpm Nm (ftlb.) rpm kW/l rpm rpm kg

M96/70 100 (3.94) 76.4 (3.01) 3600 (219.7) 9.4:1 309 6000 560 (57.08) 27004600 85.8 6750 740 40

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Engine design

Type Crankcase Cylinder housing Crankshaft Crankshaft bearings Conrod bearings Connecting rods Cylinder Cylinder head Camshaft housing Valve guide Valve arrangement Valve control Camshaft

6cylinder aluminium opposedcylinder engine, water cooled, BiTurbo Vertically divided crankcase made from cast light alloy, separate cylinder housing Cast light alloy with wet light alloy bushings inserted, Nikasil coating Forged, supported by 8 bearings Plain bearings Plain bearings Forged Nikasil cylinder lining Light alloy Aluminium alloy Pressed in 2 inlet valves suspended in parallel V arrangement 2 exhaust valves suspended in parallel V arrangement Via flatbase tappets From the crankshaft via a gear wheel to the intermediate shaft, and from there to the exhaust and inlet camshafts via one double chain each. Inlet opens 10 before TDC 58

Engine

einordnung Timing with 1 mm valve travel Inlet closes 20 after BDC Outlet opens 41 before BDC Outlet closes 9 before TDC Tunedintake system

Intake system

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Engine cooling

Engine cooling

Water cooling; 3 radiators in front of the front wheels. Two electric fans, controlled in three stages

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Engine lubrication

Type Oil cooling Oil pressure at n=5000 rpm, T=90C Oil pressure indicator Oil consumption

Dry sump lubrication with separate oil canister Via oilwater heat exchanger on pressure side behind oil pump Approx. 6.5 bar Oil pressure indicator lamp plus instrument Approx. 1.0 l/1000 km

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Engine control

Engine control module Ignition Firing order Spark plugs Electrode gap Egas USA version Boost pressure control

Bosch ME 7.8 DME, individual spark coils, knock control 162435 Bosch FR 6 LOC Beru 14 FR 6 LDU 1.60.2 mm (0.060.008 in) Electronic throttle actuator control via DME ME 7.8 OnBoard Diagnosis II Absolute pressureguided turbocharger control

Engine design

59

einordnung top of page

Fuel system

Injection

ME 7.8 (DigitaleMotorElectronic engine control module ECM) Injection valves controlled sequentially Fuel supply 1 electrical internal gear pump with 2 additional sucking jet pumps Fuel ROZ 98 required

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Electrical system

Radio interference suppression Rated voltage Battery capacity Starter Generator output

ECER 10 and 95/54/EC 12 V 80 Ah (380 A) 1.7 kW 1680 W

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Exhaust system

Exhaust system

2pipe, 3way catalytic converter exhaust system, rear mufflers

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Emission control

EURO II USA LEV

Stereo oxygen sensor closedloop control and 3way catalytic converter system, each with a 2stage catalytic converter on left+right, Secondary air system, Europe OBD Stereo oxygen sensor closedloop control and 3way catalytic converter system, each with a 2stage catalytic converter on left+right. Secondary air system, OBD II + ORVR

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Engine control

60

Precautionary measures when working on fuel system

Caution CAUTION Danger of fire and injury! Danger of fire due to escaping fuel, e.g. on hot engine components or due to electrostatic charge. Danger of fire due to naked flame and flying sparks, e.g. during welding or sanding work Secure the vehicle, e.g. with a warning sign illustration below . Wear protective gloves that are fuelresistant. 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 lines or fuel hoses, reduce the fuel pressure. Collect emerging fuel, absorb it if necessary with a suitable binding material and dispose of fuel properly. Pay attention to cleanliness when working on the fuel system.

Secure vehicle with warning sign

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Precautionary measures when working on fuel system

61

03 Diagnostic system: reading out fault memory

Reading out fault memory top of page

Reading out fault memory

The method of reading out the fault memory is described in the operating instructions for the Porsche System Tester 2. The operating instructions are supplied with each Tester. The Porsche System Tester 2 is connected to the vehicle via a 16pin diagnosis socket. The diagnosis socket is located inside the vehicle below the instrument panel near the driver (lefthand drive vehicles) or the passenger (righthand drive vehicles) Arrow . 1. Start Porsche System Tester (PST) and follow the instructions on the Tester. 2. Select vehicle type, click >> and perform the automatic control module search. 3. If a star appears in front of the relevant control module, read out the fault memory. Follow the PST instructions.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 Diagnostic system: reading out fault memory

62

03 General maintenance: test drive

Note Note The following test items are included in the test drive. Actuating the remote control of the central locking and checking operation. Front seats: Checking adjustment possibilities for operation. Checking footbrake operation and actuation travel. Starting engine, checking operation. Actuating clutch, checking operation. Actuating 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 checking operation. Actuating PSM switch during the test drive and checking operation. Checking operation of heating adjustment when engine is warm. Checking operation of airconditioning system when the engine is running. Checking operation of the instruments.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 General maintenance: test drive

63

03 Removing and installing drive belt

Removal overview of the drive belt (engine installed) Installation 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 Removing air cleaner assembly 2 Loosening servo pump wheel 03 Removing and installing drive belt 64

einordnung 3 Relieving drive belt 4 Removing servo pump wheel 5 Removing drive belt Check the drive belt for any cracks, flaws, and other damage. Replace if necessary. Note The drive belt must 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.

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Installation overview of the drive belt (engine installed)

Note When inserting the drive belt, it is essential to observe the correct contact surface on the drive belt!

Removal overview of the drive belt (engine installed)

65

einordnung

1 2 3 4 5

Fitting the drive belt Positioning servo pump wheel Tensioning the drive belt Tightening the fastening screws on servo pump Installing the air cleaner assembly

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation overview of the drive belt (engine installed)

66

94 56 19 Removing and installing bulb for direction indicator light

Removing bulb for direction indicator light Installing bulb for direction indicator light top of page

Removing bulb for direction indicator light

1. Switch off light. Remove main headlight.

2. Turn bulb socket counterclockwise 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 that it is correctly seated (bayonet lock). 2. Rotate bulb socket clockwise and engage. 3. Install main headlight and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 56 19 Removing and installing bulb for direction indicator light

67

03 Changing the engine oil and oil filter

Caution WARNING Danger of scalding from draining oil! Wear protective equipment specified.

1. Undo the oil drain plug on the crankcase and drain off the engine oil.

2. Undo the oil drain plug on the oil container and drain off the oil. An openended wrench must be used to counter it in order to avoid damage to the oil container.

3. Drain engine oil from the turbochargers. To do this, unscrew the oil drain plugs on the oil collection containers and drain the oil.

03 Changing the engine oil and oil filter

68

einordnung

4. Loosen the oil filter with special tool release key 9204 . 5. Change the oil filter element. To do this, pull the oil filter element out and replace the filter element and the two Orings.

1 2 3 4 5

Oil filter cover Oring 71.5 x 3.5 Oring 10 x 2 Oil filter element Oil filter housing

03 Changing the engine oil and oil filter

69

einordnung

Remove the remaining quantity of oil from the oil filter housing by suction. 6. Clean oil drain plugs. Always replace the sealing rings. Make sure that the sealing ring on the oil container is 2 mm thick. Tighten the drain plug on the crankcase to 70 Nm (52 ftlb.) those on the oil container to 60 Nm (44 ftlb.), and the drain plugs on the turbocharger to 30 Nm (22 ftlb.). Counter with a wrench when tightening the drain plug on the oil tank.

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 engine oil slowly in order to allow the oil sufficient time to flow from the oil container into the crankcase.

8. Check the oil level. Check oil level on the instrument cluster and correct. Seven segments must be displayed in the instrument cluster. Note This cannot be checked with the oil dipstick The vehicle must stand horizontally The engine must be idling during the check. 03 Changing the engine oil and oil filter 70

einordnung The vehicle must not be moved during the check

Location Oil drain plug on crankcase Oil drain plug for oil container Oil drain plug for turbocharger Oil filter cover

Thread M20 x 1.5 M20 x 1.5 M18 x 1.5

Tightening torque Nm (ftlb.) 70 (52) 60 (44) 30 (22) 25 (19)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

03 Changing the engine oil and oil filter

71

03 Changing the engine oil (without oil filter)

Caution WARNING Danger of scalding from draining oil Wear protective clothing specified!

1. Undo the oil drain plug on the crankcase arrow and drain off the engine oil. Then equip the drain plug with a new sealing ring and tighten to a torque of 70 Nm (52 ftlb.).

2. Undo the oil drain plug on the oil container and drain off the oil. It is absolutely necessary to counter with a wrench when undoing or tightening the oil drain plug 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, unscrew the drain plugs and drain the oil from the collection containers. Subsequently equip the drain plugs with new seals and fit them. Tightening torque: 30 Nm (22 ftlb.). Note Always replace sealing rings! 4. Fill in engine oil. Slowly fill 7.8 litres of engine oil into the oil tank. Then start the engine, check the engine oil pressure and allow the engine to warm up until the engine oil reaches a temperature of approx. 80 C.

03 Changing the engine oil (without oil filter)

72

einordnung

5. Check engine oil level. Check engine oil level on the instrument cluster. Top up engine oil until the 7th segment of the onboard computer display lights up. The following conditions must be maintained for the measurement. 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 change quantity (without oil filter change) is approx. 7.8 litres after a dripping time of 20 minutes!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

03 Changing the engine oil (without oil filter)

73

03 Replacing spark plugs

Removing spark plugs Installing spark plugs top of page

Removing spark plugs

CAUTION Danger of material damage if the vehicle is raised incorrectly or if the vehicle is driven incorrectly onto the lifting platform! Lift the vehicle only at the takeup points shown in the figure! When driving onto a platform lift, ensure that there is sufficient distance between the platform lift and the vehicle!

Item A

Special tool designation Spark plug socket wrench S 9706 KA

Remarks Refer to Workshop Equipment Manual, Chapter 2.4, Nos. 14 and 15

Note Only this spark plug wrench was tested and approved! 1. Remove rear spoiler and centre heat shield 63 55 19 Removing and installing rear spoiler . 2. Lift the vehicle. 3. Remove charge air cooler. 03 Replacing spark plugs 74

einordnung

4. Remove heat shield. Remove the heat shields located above the exhaust system. 5. Remove shield. Remove the shields above the plug coils. Unscrew the two hexagon head bolts 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 commercially available tool spark plug socket wrench No.14 , as stated above. top of page

Installing spark plugs

1. Put on spark plugs by hand.

2. Removing spark plugs 75

einordnung Tighten spark plugs with commercially available tool spark plug socket wrench No.14 .

3. Push on the ignition coils again. 4. Tighten hexagon socket heat bolts arrows for the ignition coils to 10 Nm (7.5 ftlb.). 5. Fit shields. Reinstall the shields above the ignition coils 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 the vehicle. Location Screws for ignition coils Screws for shield New spark plug Old spark plug Thread M6 M6 Tightening torque Nm (ftlb.) 10 (7.5) 10 (7.5) 30 + 3 (22 + 2) 25 + 3 (19 + 2)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing spark plugs

76

03 Checking cooling system

Coolant: checking level, antifreeze content and leaks top of page

Coolant: checking level, antifreeze content and leaks

Note The coolant filled in at the factory is intended for lifetime cooling and, thus, need not be changed. The coolant must not be mixed with other coolants. Only original Porsche antifreeze should be used when changing or topping up the coolant.

1. Check antifreeze content: Open the lid on the coolant expansion tank and check 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 device with the adapter to the coolant expansion tank and allow a test pressure of approx. 1 bar to build up. During the leak test on all hose connections, check the tightness of the hose clamps and the condition of the coolant hoses.

3. Check cooling openings for external contamination: the cooling openings must not be excessively dirty. If needed, clean these with a vacuum cleaner and a crevice nozzle made by the Krcher company see 03 Checking cooling system 77

einordnung Workshop Equipment Manual, Chapter 2.4, No. 160

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Coolant: checking level, antifreeze content and leaks

78

03 Replacing air cleaner element

Removing air cleaner Installing air cleaner top of page

Removing air cleaner

1. Pull off hot 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 and the intake pipe. Unclip the retaining clips using a screwdriver and pull out the hose. 03 Replacing air cleaner element 79

einordnung Refit the retaining clips immediately.

3. Undo hose clamp. Undo the hose clamp arrow between the air cleaner housing and the intake pipe.

4. Remove air cleaner housing. Unscrew the fastening screw M6 x 34 at the 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 flow meter cable. a. Open the omega clip on the left side of the air cleaner housing and take out the cable. b. Take the air cleaner housing out of the engine compartment.

Removing air cleaner

80

einordnung

7. Open air cleaner housing. To do this, open 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 cleaner

Installing air cleaner

81

einordnung

1. Insert filter element. a. Insert the filter element into the cleaned 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 housing side and then close the clip.

Installing air cleaner

82

einordnung

3. Place the air cleaner housing in the engine compartment as shown and move into installation position. c. Turn the housing to the right by 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 connecting hose. Reconnect the plug on the hot film mass air flow sensor. Note The plug must engage audibly!

Installing air cleaner

83

einordnung

6. Attach 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

Installing air cleaner

84

03 Replacing the fuel filter

1. Disconnect plug on the hot film mass air flow meter. To do this, push the plug downwards and press on 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 pipe. To do this, unclip the retaining clip using a screwdriver and pull out the hose. Refit 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 pipe.

5. Tilt air cleaner housing outwards. To do this, tilt the housing upwards on the right by 90 and then turn the housing 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 of the engine compartment.

03 Replacing the fuel filter

85

einordnung

7. Pull off the ground cable from the fuel filter.

8. Undo fuel pressure line. Make sure to counter with a wrench when doing this. Collect emerging fuel.

9. Disconnect 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 the filter with holder. 11. Remove fuel filter. To do this, fully open the restraining strap and take the fuel filter out.

03 Replacing the fuel filter

86

einordnung

12. Push the new fuel filter into the restraining strap and tighten again. Position the filter in such a way that the mark arrows on the filter is aligned with the outer edge of the holder in installation position. 13. Position 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 connector must engage audibly. Pull slightly to ensure that the connection is properly locked.

15. Tighten fuel pressure line. Make sure to counter with a wrench when doing this.

16. Connect the ground cable to the filter. 17. 03 Replacing the fuel filter 87

einordnung Clip in hot film mass 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.

18. Place the air cleaner housing in the engine compartment as shown and move into installation position. To do this, first turn the housing to the 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. Reconnect the plug on the hot film mass air flow sensor. The connector must engage audibly.

21. Attach the connecting hose between the left turbocharger and the intake distributor. The hose must engage audibly.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

03 Replacing the fuel filter

88

03 Clutch: checking the play and pedal end position

Checking clutch free play Checking the pedal end position (pedal return/return force) top of page

Checking clutch free play

The clutch master cylinder has an inner stop. The push rod and the clutch pedal are always pressed against this stop by the boost spring. Due to the automatic hydraulic adjustment of the clutch, it is not possible to determine the clutch play by checking at the clutch pedal. top of page

Checking the pedal end position (pedal return/return force)

Check that the pedal is in end position 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 clutch push rod and the boost spring are not adjustable. The boost spring has 2 functions, namely to provide pedal force assistance and to return the pedal. The following are some of the points which are requirements for perfect clutch operation: Correct bleeding of the clutch hydraulics. No leaks in the hydraulic system. Pedal return to the starting position. Installation position of the pedals in accordance with the series condition.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 Clutch: checking the play and pedal end position

89

03 Changing transmission oil

Changing transmission oil Tightening torques top of page

Changing transmission oil

Note Top up only with transmission oil approved by Porsche. See Parts Catalogue! Filling capacity: 3.8 litres Change quantity: 3.0 litres 1. Place oil collection pan under the transmission.

2. Unscrew the oil filler 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 bottom edge of the oil filler opening. 6. Tighten filler plug to 30 Nm (22 ftlb.). top of page

Tightening torques

Location Filler plug for transmission oil Drain plug for transmission oil

Thread M22 M22

Tightening torque Nm (ftlb.) 30 (22) 30 (22)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

03 Changing transmission oil

90

03 Checking and topping up the ATF

Tools Checking and topping up the ATF Tightening torques top of page

Tools

Item

Special tool designation Connection hose 9507/1

Remarks

top of page

Checking and topping up the ATF

Note Top up only with ATF approved by Porsche. See Parts Catalogue!

03 Checking and topping up the ATF

91

einordnung

Note

The stipulated fluid level is extremely important for perfect functioning of the automatic transmission. It is correct if there is a slight amount of ATF escaping at the control screw bore B at temperatures between 30 C and 40 C. Testing conditions: The transmission must not be in the reduced driving program. The ATF temperature must be between 30 C and 40 C. An ATF inspection at an insufficient ATF temperature causes overfilling and an inspection at an excessive ATF temperature causes insufficient filling. Selector lever in position "P" and engine idling. The airconditioning 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 Tester 2 and call up the ATF temperature. Note The ATF temperature must not be higher than 40 C at the start of the test. 3. Move selector lever to position "P" and allow engine to idle. WARNING Danger of injury from emerging ATF fluid! ATF fluid can cause burns and chemical burns to the eyes! Wear protective goggles

4. Unscrew control screw B . If ATF escapes from the control bore and if the ATF temperature is 30 C to 40 C, the ATF level is Ok. If there is enough ATF fluid in the transmission, then continue Checking and topping up the ATF 92

einordnung with step 10. Note The control screw must be closed no later than when an ATF temperature of 45 C is reached. 5. If no ATF escapes from the control bore even though approx. 40 C has been reached, the ATF must be topped up. Note To undo and tighten the cap nut for the charging valve, counter with an openended wrench. 6. Screw off cap nut for the charging valve.

7. 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 charging valve. Tightening torque: 40 Nm (30 ftlb.) 10. Screw in ATF control screw with a new sealing ring. Tightening torque: 22 Nm (16 ftlb.) top of page

Tightening torques

Location Control screw to ATF pan Cap nut to charging valve

Thread M10 M14 x 1.5

Tightening torque Nm (ftlb.) 22 (16) 40 (30)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

93

03 Replacing ATF
Tools Replacing ATF fluid Tightening torques top of page

Tools

Item

Special tool designation Connection hose 9507/1

Remarks

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: approx. 4.5 litres 1. Place oil collection pan under the transmission.

03 Replacing ATF

94

einordnung

2. Unscrew drain screw A and drain ATF. Note Without ATF, the engine must not be started and the vehicle must not be towed. 3. Replace sealing ring for drain plug and screw in plug. Tightening torque: 22 Nm (16 ftlb.)

4. Unscrew control screw B . Note To undo and tighten the cap nut for the charging valve, counter with an openended 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 the charging valve until surplus ATF runs out at the control screw bore. Note All instructions and test conditions for "Checking and topping up ATF fluid" must be observed for further work steps (see Serv. No. 370235).

Replacing ATF fluid

95

einordnung 7. Connect the Porsche System Tester 2 and call up the ATF temperature. 8. Move selector lever to position "P" and allow engine to idle.

9. With engine running, top up ATF again until excess ATF emerges from the bore of the ATF control screw B . 10. With the brake pedal pressed, change through all selector lever positions, remaining in each position for approx. 10 s. Note The ATF temperature must not be higher than 40 C at 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 torque: 40 Nm (30 ftlb.) 13. Screw in the ATF control screw with a new sealing ring and tighten it to 20 Nm (15 ftlb.). Tightening torque: 22 Nm (16 ftlb.) top of page

Tightening torques

Location Drain plug to ATF pan Control screw to ATF pan Cap nut to charging valve

Thread M10 M10 M14 x 1.5

Tightening torque Nm (ftlb.) 22 (16) 22 (16) 40 (30)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

96

03 Removing and installing ATF filter

Tools Removing ATF filter Installing ATF filter Tightening torques top of page

Tools

Item

Special tool designation Connection hose 9507/1

Remarks

top of page

Removing ATF filter

1. Remove underbody panels, rear and centre.

2. Remove cross member. 03 Removing and installing ATF filter 97

einordnung 3. Disengage cable on the retaining clips of the ATF pan. 4. Place oil collection pan under the transmission.

5. Unscrew drain screw A and drain ATF. Note Without ATF, the engine must not be started and the vehicle must not be towed. 6. Remove ATF pan (loosen screws crosswise).

7. Remove ATF filter. top of page

Installing ATF filter

1. Thinly 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 torque: 8 Nm (6 ftlb.) 4. Replace sealing ring for ATF drain plug and tighten screw. Tightening torque: 22 Nm (16 ftlb.) 5. Fill in ATF. => Checking and topping up the ATF 6. Engage cable on the retaining clips of the ATF pan. 7. Install cross member. Tightening torque: 65 Nm (48 ftlb.) 8. Install rear underside panel.

Removing ATF filter

98

einordnung top of page

Tightening torques

Location Drain plug to ATF pan ATF pan to transmission Transmission cross member to body

Thread M 10 M6 M 10

Tightening torque Nm (ftlb.) 22 (16) 8 (6) 65 (48)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing ATF filter

99

03 Replacing and checking transmission oil in final drive

Tools Changing transmission oil in final drive Tightening torques top of page

Tools

Item

Special tool designation Filling system V.A.G 1924

Remarks

top of page

Changing transmission oil in final drive

Note Use only oils approved by Porsche. See Parts Catalogue! Filling capacity: 1.2 litres

03 Replacing and checking transmission oil in final drive

100

einordnung

1. Unscrew oil filler plug A .

2. Unscrew oil drain plug arrow . Drain oil with vehicle standing horizontally. 3. Clean the drain plug and filler plug. 4. Replace sealing rings for the drain plug and filler plug. Note Attach the special tool as high as possible 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 opening and use it to read the oil level. 7. Screw in and tighten the filler plug and drain plug. Filler plug tightening torque: 22 Nm (16 ftlb.) Drain plug tightening torque: 25 Nm (19 ftlb.) top of page

Changing transmission oil in final drive

101

einordnung

Tightening torques

Location Oil drain plug Oil filler plug

Thread M21 x 1.5 M18 x 1.5

Tightening torque Nm (ftlb.) 25 (19) 22 (16)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

102

03 Changing transmission oil in front wheel drive

Changing transmission oil in front wheel drive Tightening torques top of page

Changing transmission oil in front wheel drive

Note Use only oils approved by Porsche. See Parts Catalogue! 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 filler plug. 5. Fill with oil up to the bottom edge of the oil filler opening. 6. Tighten the drain plug and filler plug. Tightening torque: 28 Nm (21 ftlb.). top of page

Tightening torques

Location Screw plug, oil drainage and oil filling

Thread M18

Tightening torque Nm (ftlb.) 28 (21) 103

03 Changing transmission oil in front wheel drive

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

104

03 Changing transmission oil GT2

Changing transmission oil GT2 Topping up transmission oil GT2 Tightening torques Total capacity: 3.7 + 0.1 litres Oil change quantity: 3.2 + 0.1 litres Note Use only oils approved for this type by Porsche. See Parts Catalogue.

top of page

Changing transmission oil GT2

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. Clean the drain plug and filler plug. 2. Screw in oil drain plug again and top up oil to the bottom edge of the oil filler opening. Tightening torque: 30 Nm (22 ftlb.) 3. Screw in oil filler plug. Tightening torque: 30 Nm (22 ftlb.) 4. Fit underbody trim parts. top of page

03 Changing transmission oil GT2

105

einordnung

Tightening torques

Location Oil filler plug Oil drain plug

Thread M22 x 1.5 M22 x 1.5

Tightening torque Nm (ftlb.) 30 (22) 30 (22)

996840, 996841

Tightening torques

106

03 Steering gear: fluid level and bellows

Power steering: checking the fluid level Steering gear: visual inspection of the bellows top of page

Power steering: checking the fluid level

General
Damage to the power steering is caused by a shortage of oil in the hydraulic system. Even small leaks can cause the fluid to escape and damage the servo pump as a result of the high oil pressure occurring in the hydraulic circuit. Gruntlike noises that can be heard when the steering is locked, or foam formation in the reservoir indicate a shortage of oil and/or that air has also been sucked 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 steering is supplied from the collective supply tank A located in the engine compartment, but also the hydraulic clutch boost. The supply tank for GT2 has a different form. It is located in the engine compartment. Only Pentosin CHF 11 S may be used in the reservoir. Pentosin CHF 11 S can be ordered with the following part number: Quantity supplied 1 litre = 000.043.203.33. Note There is a second tank for clutch operation for the Turbo. This container is located in the luggage compartment (under a cover).

Power steering: checking the fluid level

03 Steering gear: fluid level and bellows

107

einordnung

There are two marks on the dipstick located on the reservoir cap. One side bears the mark Cold for a cold engine (approximately 20 C) and the other Hot for a hot engine (approximately 80 C). Check the fluid level (Pentosin CHF 11 S) with the engine stationary and cold (approx. 20 C). CAUTION Danger of damage to property if too much Pentosin CHF 11 S is filled or if it comes in contact with the coolant hoses when topping up or filling in. Observe the following specifications in order to avoid overfilling and thus overflowing. Multiple steering operations (manoeuvring) or/and actuating the clutch with the engine switched off change the fluid level in the reservoir (actuating the clutch is not valid for the GT2). Fluid 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 IMMEDIATELY. Replace visibly swollen coolant hoses. 1. Start engine and run it at idle speed for approx. 20 seconds. Switch off engine. 2. Open the engine cover.

3. Open reservoir cap. 4. Wipe off the dipstick. Close and then reopen the cap. The fluid level should lie in the hatched area beneath the "Cold" mark (mark = maximum level at 20 C). Top up with Pentosin if necessary. *The upper "Hot" mark is intended for a fluid temperature of 80 C. Do not add too much Pentosin! The respective marks are for the maximum fluid level at the "COLD" or "HOT" temperature. If assembly work was performed previously, check the fluid level with the engine idling and without operating the steering.

top of page

Power steering: checking the fluid level

108

einordnung

Steering gear: visual inspection of the bellows

Note The bellows on the steering gear can be damaged by outside 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, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Steering gear: visual inspection of the bellows

109

03 Axle joints/drive shafts

Tie rod ends: checking the play and dust bellows Axle joints: checking the play and dust bellows Drive shafts: visual inspection of the boots top of page

Tie rod ends: checking the play and dust bellows

Note The rubber dust bellows and bellows on the steering gear and on the tie rods can be damaged by external influences, e.g. stone impact, or during assembly work. If a rubber dust bellow leaks, the joint or the tie rod must be replaced, because any dirt or moisture that seeps in will destroy the joint. 1. Check the play and dust bellows. 2. Check that the dust bellows, bellows and joints are in working order and ensure that they are free of leaks. top of page

Axle joints: checking 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 hidden cracks. If a rubber dust bellow leaks, the corresponding joint or control arm must be replaced, because any dirt or moisture that seeps in will destroy the joint. CAUTION Danger of material damage if the vehicle is raised incorrectly or if the vehicle is driven incorrectly onto the lifting platform. Lift the vehicle only at the takeup points provided. Make sure the screw connections for the diagonal braces are accessible. When driving onto a platform lift, ensure that there is sufficient distance between the platform lift and the vehicle. In order to avoid damage to the side members and side member panels, the mounting plates of the platform lift must be raised!

03 Axle joints/drive shafts

110

einordnung 3. Inspect the dust bellows of the axle joints (ball joints) on the suspension (front and rear) as follows: Put the vehicle onto a lifting platform with the steering lock disengaged. Perform a visual inspection after cleaning. Note In the vicinity of the brake cover panels, no visual inspection is possible in a small area. Check this area by touch. 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 front wheels to the other steering stop, check the other half of each rubber dust bellows.

top of page

Drive shafts: visual inspection of the boots

Perform a visual inspection of the boots for leaks and damage.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Axle joints: checking the play and dust bellows

111

03 Running gear adjustment/storage of assemblies

Running gear adjustment (wheel alignment values) Storage of assemblies and running gear top of page

Running gear adjustment (wheel 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

Visual inspection of all rubber mounts for damage.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 Running gear adjustment/storage of assemblies

112

03 Tyres and spare wheel: checking condition and tyre pressure

Checking condition Tyre pressure for cold tyres (approx. 20 C) top of page

Checking condition
Tyres are a safety element that fulfil the demands placed on them only if they have the correct air pressure and a sufficient tread depth. WARNING Danger of injury and damage to property as a result of modified handling behaviour if the pressure in the tyres falls below the minimum values. Danger of injury and damage to property as a result of modified handling behaviour in the case of insufficient 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 the tyres must be carried out. 1. Check condition and tyre pressure. Valve caps protect the valve from dust and dirt and therefore from damage. 2. Always screw on valve caps tightly and replace missing valve caps. top of page

Tyre pressure for cold tyres (approx. 20 C)

911 Turbo
18inch wheels, summer and winter tires Front 2.5 bar overpressure Rear 3.0 bar overpressure Collapsible wheel front/rear 2.5 bar overpressure for 16 inch 2.8 bar overpressure for 17 inch

911 GT2 (M002/M003)

Note

03 Tyres and spare wheel: checking condition and tyre pressure

113

einordnung 911 GT2 M002 = road version 911 GT2 M003 = Club Sport version 18inch wheels, summer and winter tires Front 2.2 bar overpressure Rear 2.7 bar overpressure Collapsible wheel not present

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 event of damage, observe without fail the safety and operating instructions.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

911 GT2 (M002/M003)

114

03 Checking and changing the brake fluid

Checking the brake fluid level Changing the brake fluid top of page

Checking the brake fluid level

1. Visually inspect brake fluid level.

Note

The brake fluid level must be between min. and max.. Observe brake fluid quality. Use only new DOT 4 brake fluid. This brake fluid is available under the following part numbers: quantity supplied 1 litres = 000.043.203.66 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 DOT 4 brake fluid. The brakefluid change interval using Super DOT4 brake fluid is two years. This brake fluid is available under the following part numbers: quantity supplied 1 litres = 000.043.203.66 container volume. 30 litres = 000.043.203.67. 1. Fill reservoir to its top edge with new brake fluid. 2. Connect a bleeding device to the brake fluid reservoir.

03 Checking and changing the brake fluid

115

einordnung

3. Switch on the bleeding device. Bleeding pressure is approximately 2.0 bar. Note Drain brake fluid on every brake caliper on both bleeder valves. Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for cleanliness, lack of air bubbles 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, bubblefree brake fluid emerges and until the corresponding change quantity per brake calliper is reached (approx. 250 cm3 ).

6. Switch off and disconnect the bleeding device. Correct the brake fluid level if necessary.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Changing the brake fluid

116

03 Parking brake: checking the free play of the parking brake lever
Parking brake: checking the free play of the parking brake lever top of page

Parking brake: checking the free play of the parking brake lever
Checking the free play of the handbrake lever. The parking brake has asbestosfree brake linings. Note The handbrake with asbestosfree brake linings must never be adjusted in such a way that the lining must grind down during operation. The handbrake must be adjusted if the handbrake lever can be pulled up by more than 4 teeth with medium force application (without a braking 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 turnbuckle accessible, open the cover of the tray behind the parking brake lever and remove the rubber inlay and also the insert.

3. Undo the adjustment nuts arrow on the turnbuckle until the cables are without pretension. 4. With a screwdriver Figure , turn the adjustment device through a wheel bolt threaded hole so that the brake disc can no longer be moved. 5. Turn back the adjustment fixture through 5 notches again (release approx. 3 notches until the brake disc can be moved freely, then release another 2 notches).

03 Parking brake: checking the free play of the parking brake lever

117

einordnung

6. Repeat the procedure on the other wheel. 7. Pull up the parking brake lever by 2 teeth and adjust 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, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Adjusting the parking brake

118

03 Visual inspection: brake lines/brake pads/brake discs

Brake hoses and lines Brake system: visual inspection of the brake pads and brake discs for wear top of page

Brake hoses and lines

Carry out visual inspection for leaks, damage, routing and corrosion. top of page

Brake system: visual inspection of the brake pads and brake discs for wear
WARNING Braking effect impaired if the brake pads are replaced too late. Braking effect impaired if the brake discs are replaced too late. Danger of injury and damage to 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 wear is indicated by the warning light, the warning contact (sender including wire and plug 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. Warning contacts must be replaced if the core of the wire is worn. However, if only the plastic part of the warning contact is worn, there is no need to replace it. 1. To check the brake pads, remove the wheels.

03 Visual inspection: brake lines/brake pads/brake discs

119

einordnung

2. Visually inspect the brake pads for 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

Brake system: visual inspection of the brake pads and brakediscs for wear

120

03 Checking the wheel mounting

Use suitable commercially available tools (wrench size 19 mm) together with a tested torque wrench , covering the range of 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 bolts to 130 Nm (96 ftlb.) or check for tightness.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 Checking the wheel mounting

121

03 Checking lid and doors

Checking lid lock, front and rear Checking safety hook, front lid Function test, checking door lock Functional inspection of the tank cap lock Checking door and lid tightening torques Checking inner release of luggage compartment (Trunk Entrapment) Tightening torques top of page

Checking lid lock, front and rear

Check that the lid locks engage by insertion of the lock upper parts when the lids (front and rear) are closed and that they disengage again when the lid releases are pulled.

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 7 mm Wear limit 4 mm

top of page

Checking safety hook, front lid

1. Check that the front lid is held down by the 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

Function test, checking door lock

Check that the door lock engages in two stages through the locking wedge when the doors are closed and that it disengages again when the door handle is operated (inside and outside). top of page

03 Checking lid and doors

122

einordnung

Functional inspection of the tank cap lock

Lock vehicle. Check that the tank cap lock locks the tank cap in the closed position. top of page

Checking door and lid tightening torques

Check the tightening torque of the fastening screws of the door lock, the latch striker, the lower part of the lid lock and the upper part of the lid lock. Fastening screws of upper part of the lid lock on front cover. => Tightening torques Fastening screws of lower part of the lid lock on front closing panel. => Tightening torques => Tightening torques Fastening screws of latch striker on side section. => Tightening torques top of page

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 lid will open completely after 30 seconds. The luggage compartment will impact in front of the windscreen 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 the lower part of the lock.

1. Engage the upper part of the lock No. 996 551 051 02 = tool (Porsche spare part) in the lower part of the lock direction of arrow . 2. Unlock unlocking lever in the luggage compartment. Check whether the upper part of the lid lock disengages automatically. top of page

Functional inspection of the tank cap lock

123

einordnung

Tightening torques

Location Fastening screws of upper part of the lid lock on front cover Fastening screws of lower part of the lid lock on front closing panel Fastening screws on door lock on the doors Fastening screws of latch striker on side section

Illustration Thread M6 M6 M8 M8

Tightening torque [Nm] (ftlb.) 10 (7.5) Nm (ftlb.) 10 (7.5) Nm (ftlb.) 20 +2 (15 + Nm 1.5) (ftlb.) 23 (17) Nm (ftlb.)

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841, 996620, 996621, 996650, 996651, 996630, 996631

Tightening torques

124

03 Checking seat belts

Functional inspection Condition inspection top of page

Functional inspection
It must be possible to unroll the belt strap smoothly from the belt retractor via the deflector fitting by pulling evenly, and the tongue 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 damage If it displays evidence of damage in the form of cuts, fraying, seam tears etc., the seat belt must be replaced

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841, 996620, 996621, 996650, 996651, 996630, 996631

03 Checking seat belts

125

03 Inspecting the airbag system

Visual inspection Checking airbag warning light Function test of the airbag system top of page

Visual inspection
1. Check airbag units visually: a. Check that a trim or stickers are not attached to the airbag units (driver's, passenger's, side airbag). b. Visual inspection of the components for damage and deformation. c. The system check must be acknowledged in the stamp spaces provided in the Guarantee and Maintenance booklet. top of page

Checking airbag warning 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 the light unit and power supply.

top of page

Function test of the airbag system

1. Function test of the airbag system: CAUTION Danger of injury and damage to property as a result of incorrect handling of airbag units! Always observe the safety regulations for handling airbag units 6, 69 Safety regulations for handling airbag and belt tensioner units . Connect and switch on the Porsche System Tester. Switch on ignition. Establish communication with the airbag 03 Inspecting the airbag system 126

einordnung control module. Read out fault memory: No fault stored. Pull off fuse according to the circuit diagram. 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, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Function test of the airbag system

127

03 Passenger protection maintenance: checking rollover protection system

Caution WARNING Risk of injury if the rollover bar is triggered! > All persons must remain out of the operating range of the rollover bar during diagnosis. > Always keep the operating range of the rollover bar free (do not leave tools there). > Install, remove and transport the rollover bar only when it is extended (triggered). > Repairs to the rollover bar and actuators are not permitted. Note The rollover bar must be triggered every two years at the latest, using the Porsche System Tester. Perform the function test on the rollover 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 the vehicle. 2. Switch on ignition. 3. Select menu item Rollover protection . 4. Select the function drive links in the command line which appears. 5. Press the key combination described in the Tester; the rollover protection system is triggered. 6. Pressing in the rollover bar: press locking levers outward and press in the rollover bar until it can be felt to engage. 7. Fit cover caps on the left and right.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841, 996620, 996621, 996650, 996651, 996630, 996631

03 Passenger protection maintenance: checking rollover protection system

128

03 Particle filter: replacing the filter element

Removing particle filter Installing particle filter Replacing filter element (with and without carbon). Note The particle filter is installed on the right in front of the heating/airconditioning system!

top of page

Removing particle filter

1. Remove the cover for the heating and airconditioning system. 2. In conjunction with telephone preparation, loosen 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

Installing particle filter

1. Insert a new particle filter into the housing guide. 2. Check that the filter is correctly fitted and in the correct installation position. 3. Insert antenna part at the top, screw in both top and bottom fastening screws. Tightening torque 6 Nm (4.5 ftlb.).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 Particle filter: replacing the filter element

129

03 Checking the function of the vehicle's lights

Adjusting the main headlights Setting Adjusting the main headlights, USA version Fog light adjustment Removing main headlight Installing main headlight top of page

Adjusting the main headlights

1. Open the luggage compartment lid. 2. Remove the luggage compartment mat on the wheel housing wall.

3. Open the cover for 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 (headlight beam adjustment)! Use a standard 5 mm ballhead screwdriver to make the headlight adjustment (free blade length 150 mm)! Only the lower screw may be turned for height adjustment; for lateral adjustment the upper and lower screws must be turned in the same direction and for the same number of rotations!

03 Checking the function of the vehicle's lights

130

einordnung 5. Make the adjustment 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. A Lateral adjustment B Height and lateral adjustment C Fog light adjustment top of page

Setting
Note Set the headlight adjustment unit to 10 cm/10 m (1%)! With this alignment, preference must be given to the central zone around the salient point of the light/dark limit! First, make the vertical adjustment of the dipped beam headlights. 1. To do this, line up the light/dark borderline running upwards at an angle on the righthand 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 driving on the right) with the dotted horizontal line of the adjustment unit. Note The distance between the headlights and the adjustment unit should be as small as possible! It should not exceed 30 cm, because if the distance is greater, it is no longer possible to define the formation of the light/dark limit in the adjustment unit clearly! 3. Secure the plugs after making the adjustment. 4. In the case of Xenon headlights, 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

131

einordnung

Adjusting the main headlights, USA version

Note A new adjustment may only be made in the case of accident repairs or replacement of the main headlights! Vertical and horizontal adjustment must be carried out with a headlight adjustment unit. top of page

Fog light adjustment

Note The vehicle must be on a horizontal surface!

Make the adjustment 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 adjustment Note Switchedon headlights must not be covered by a front apron or film!

top of page

Removing main headlight

Note Risk of damage to headlights due to chafing and excessive temperatures. Headlights must not be covered when they are switched on, e.g. wing protection or film.

Adjusting the main headlights, USA version

132

einordnung

1. Release the side carpet by unscrewing plastic nut A arrow .

2. Pull rubber stopper B off the release opening.

3. Place the socket wrench from the tool kit on the release axle. 4. The toggle of the socket wrench should point 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 wrench back until it points vertically arrow B downwards. top of page

Installing main headlight

Note Do not attach any covers (e.g. stone shields or films) in the area of the headlights.

Removing main headlight

133

einordnung

1. Insert the headlight into the guide rails and push it fully into the wing arrow . 2. Press the headlight to the rear, turning the socket wrench at the same time until the wrench points horizontally to the rear 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 rubber stopper in the release opening. 5. Screw the side carpet tight with the plastic screw A .

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing main headlight

134

03 Windscreen wiper/washer system, headlight washer

Caution CAUTION Danger of material damage if headlights are cleaned incorrectly! Use only soapy water to clean the exterior lights and the plastic headlight lenses! Never use chemical cleaning agents! To avoid scratches, do not rub with dry or only damp cloths, paper towels or insectremoval sponges! Note The headlight washer nozzles are preset! It is not necessary to adjust them! Check the function, fluid levels and nozzle settings.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 Windscreen wiper/washer system, headlight washer

135

03 Checking the function of electrical equipment, as well as the indicator and warning lights
Turn ignition key and check function of warning and indicator lights (visual inspection). Actuate power windows and check operation. Check that rear window heater is in working order. Adjust heater blower 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 orientation lights. Actuate central locking and check operation. Operate cigarette lighter and check that it is in working order.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 Checking the function of electrical equipment, as well as the indicator and warning lights

136

03 Additional maintenance USA

Caution Additional maintenance, replacing spark plugs Additional maintenance every 60,000 mls/96,000 km Additional maintenance every 90,000 mls/144,000 km Maintenance every 2 years Maintenance after 4, 8, 10 then every 2 years WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA Vehicles reimported 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 completeness. top of page

Additional maintenance, replacing spark plugs

Additional maintenance, replacing spark plugs => Replacing spark plugs 911 Turbo/ GT2 every 30,000mls/48,000km

OK

top of page

Additional maintenance every 60,000 mls/96,000 km

Note It is recommended to replace the fuel filter every 60,000 mls (96,000 km).

Additional maintenance every 60,000 mls/96,000 km Replace Polyrib belt => Removing and installing drive belt

OK

top of page

03 Additional maintenance USA

137

einordnung

Additional maintenance every 90,000 mls/144,000 km

Additional maintenance every 90,000 mls/144,000 km OK Manual transmission: change oil => Changing transmission oil or => Changing transmission oil GT2 Automatic transmission: change ATF and ATF filter => Replacing ATF and => Removing and installing ATF filter Automatic transmission: change oil in final drive => Replacing and checking transmission oil in final drive Final drive, front: change oil => Changing transmission oil in front wheel drive

top of page

Maintenance every 2 years

Maintenance every 2 years Change brake fluid (use only original Porsche brake fluid) => Checking and changing the brake fluid Condition report preparing longlife 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 FrenchCanadian Form WKD 444 040 02 Italian Form WKD 444 050 02 Spanish Form WKD 444 091 02 Dutch

OK

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Maintenance after 4, 8, 10 then every 2 years

Maintenance after 4, 8, 10 then every 2 years Inspect airbag system => Inspecting the airbag system Mount assemblies and running gear: visual inspection of all rubber mounts for damage => Running gear adjustment&sol;storage of assemblies

OK

996420, 996421, 996450, 996451, 996840, 996841

Additional maintenance every 90,000 mls/144,000 km

138

03 Additional maintenance as of MY 2004

Note Additional maintenance, replacing spark plugs Additional maintenance every 80,000 km/48,000 mls Additional maintenance every 160,000 km/96,000 mls Maintenance every 2 years Maintenance after 4, 8, 10 then every 2 years Note Not valid for USA. The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module).

top of page

Additional maintenance, replacing spark plugs

Additional maintenance, replacing spark plugs => Replacing spark plugs 911 Turbo/ GT2 every 40,000 km/24,000 mls

OK

top of page

Additional maintenance every 80,000 km/48,000 mls

Additional maintenance every 80,000 km/48,000 mls Replace the fuel filter => Replacing the fuel filter Replace Polyrib belt => Removing and installing drive belt

OK

top of page

Additional maintenance every 160,000 km/96,000 mls

Additional maintenance every 160,000 km/96,000 mls OK Manual transmission: change oil => Changing transmission oil or => Changing transmission oil GT2 03 Additional maintenance as of MY 2004 139

einordnung Automatic transmission: change ATF and ATF filter => Replacing ATF and => Removing and installing ATF filter Automatic transmission: change oil in final drive => Replacing and checking transmission oil in final drive Final drive, front: change oil => Changing transmission oil in front wheel drive

top of page

Maintenance every 2 years

Maintenance every 2 years Change brake fluid (use only original Porsche brake fluid) => Checking and changing the brake fluid Check rollover protection system (only 911 Turbo Cabrio) => Passenger protection maintenance&colon; checking rollover protection system Condition report preparing longlife 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 FrenchCanadian Form WKD 444 040 02 Italian Form WKD 444 050 02 Spanish Form WKD 444 091 02 Dutch

OK

top of page

Maintenance after 4, 8, 10 then every 2 years

Maintenance after 4, 8, 10 then every 2 years Inspect airbag system => Inspecting the airbag system Mount assemblies and running gear: visual inspection of all rubber mounts for damage => Running gear adjustment&sol;storage of assemblies

OK

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Additional maintenance every 160,000 km/96,000 mls

140

03 Additional maintenance USA as of MY 2004

Caution Additional maintenance, replacing spark plugs Additional maintenance every 60,000 mls/96,000 km Additional maintenance every 90,000 mls/144,000 km Maintenance every 2 years Maintenance after 4, 8, 10 then every 2 years WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA Vehicles reimported 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 completeness. top of page

Additional maintenance, replacing spark plugs

Additional maintenance, replacing spark plugs => Replacing spark plugs 911 Turbo/ GT2 every 30,000mls/48,000km

OK

top of page

Additional maintenance every 60,000 mls/96,000 km

Note It is recommended to replace the fuel filter every 60,000 mls (96,000 km).

Additional maintenance every 60,000 mls/96,000 km Replace Polyrib belt => Removing and installing drive belt

OK

top of page

03 Additional maintenance USA as of MY 2004

141

einordnung

Additional maintenance every 90,000 mls/144,000 km

Additional maintenance every 90,000 mls/144,000 km OK Manual transmission: change oil => Changing transmission oil or => Changing transmission oil GT2 Automatic transmission: change ATF and ATF filter => Replacing ATF and => Removing and installing ATF filter Automatic transmission: change oil in final drive => Replacing and checking transmission oil in final drive Final drive, front: change oil => Changing transmission oil in front wheel drive

top of page

Maintenance every 2 years

Maintenance every 2 years Change brake fluid (use only original Porsche brake fluid) => Checking and changing the brake fluid Check rollover protection system (only 911 Turbo Cabrio) => Passenger protection maintenance&colon; checking rollover protection system Condition report preparing longlife 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 FrenchCanadian Form WKD 444 040 02 Italian Form WKD 444 050 02 Spanish Form WKD 444 091 02 Dutch

OK

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Maintenance after 4, 8, 10 then every 2 years

Maintenance after 4, 8, 10 then every 2 years Inspect airbag system => Inspecting the airbag system Mount assemblies and running gear: visual inspection of all rubber mounts for damage => Running gear adjustment&sol;storage of assemblies

OK

Additional maintenance every 90,000 mls/144,000 km

142

einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Maintenance after 4, 8, 10 then every 2 years

143

03 Additional maintenance
Note Additional maintenance, replacing spark plugs Additional maintenance every 80,000 km/48,000 mls Additional maintenance every 160,000 km/96,000 mls Maintenance every 2 years Maintenance after 4, 8, 10 then every 2 years Note Not valid for USA. The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module).

top of page

Additional maintenance, replacing spark plugs

Additional maintenance, replacing spark plugs => Replacing spark plugs 911 Turbo/ GT2 every 40,000 km/24,000 mls

OK

top of page

Additional maintenance every 80,000 km/48,000 mls

Additional maintenance every 80,000 km/48,000 mls Replace the fuel filter => Replacing the fuel filter Replace Polyrib belt => Removing and installing drive belt

OK

top of page

Additional maintenance every 160,000 km/96,000 mls

Additional maintenance every 160,000 km/96,000 mls OK Manual transmission: change oil => Changing transmission oil or => Changing transmission oil GT2 03 Additional maintenance 144

einordnung Automatic transmission: change ATF and ATF filter => Replacing ATF and => Removing and installing ATF filter Automatic transmission: change oil in final drive => Replacing and checking transmission oil in final drive Final drive, front: change oil => Changing transmission oil in front wheel drive

top of page

Maintenance every 2 years

Maintenance every 2 years Change brake fluid (use only original Porsche brake fluid) => Checking and changing the brake fluid Condition report preparing longlife 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 FrenchCanadian Form WKD 444 040 02 Italian Form WKD 444 050 02 Spanish Form WKD 444 091 02 Dutch

OK

top of page

Maintenance after 4, 8, 10 then every 2 years

Maintenance after 4, 8, 10 then every 2 years Inspect airbag system => Inspecting the airbag system Mount assemblies and running gear: visual inspection of all rubber mounts for damage => Running gear adjustment&sol;storage of assemblies

OK

996420, 996421, 996450, 996451, 996840, 996841

Additional maintenance every 160,000 km/96,000 mls

145

3 Technical data
6speed manual transmission G 96.50 Front wheel drive Z 96.00 top of page

6speed manual transmission G 96.50

Type G 96.50

Code letter

Equipment 6speed

Installed in 911 Turbo (996)

Model year 2001

General data Transmission ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Reverse gear Final drive Transmission ratio, final drive Filling capacity for new filling Change quantity

Manual transmission G 96.50 Z1 : Z2 = Z2 : Z1 11 : 42 = 3.82 21 : 43 = 2.05 27 : 38 = 1.41 34 : 38 = 1.12 37 : 34 = 0.92 40 : 30 = 0.75 14 : 40 = 2.86 Hypoid bevel gear drive with 10 mm offset 9 : 31 = 3.44 3.8 l 3.0 l

3 Technical data

146

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Manual transmission tightening torques

Location Drain plug for transmission oil Filler plug for transmission oil Transmission on engine Air flanges on transmission Slave cylinder on transmission Bracket for slave cylinder on transmission Bracket for clutch control shaft on transmission Guide tube for release bearing on transmission housing Drive shaft on transmission flange Transmission support to transmission mount Transmission support to body Collar nut/halfshaft flange

Thread Tightening torque Nm (ftlb.) M22 30 (22) M22 30 (22) M10 45 (33) M6 10 (7.5) M10 x 35 45 (33) M8 x 20 23 (17) M6 x 16 10 (7.5) M6x14 10 (7.5) M10 45 (33) M10 65 (48) M10 65 (48) M20 x 1.5 120 (89)

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Front wheel drive Z 96.00

Type Z 96.00

Code letter

Equipment

Installed in 911 Turbo (996) worldwide

Model year 2001

Manual transmission tightening torques

147

einordnung General data Transmission ratio, final drive (Z2 : Z1 = i) Final drive Filling capacity Frontaxle final drive Z 96.00 31 : 9 = 3.44 Bevel gear drive without hypoid offset approx. 1.5 l

Frontaxle drive tightening torques

Location Screw plug, oil drainage and oil filling Cover on final drive Longneck tube on final drive Drive shaft on final drive Rear transmission support to transmission mount Rear transmission support on body Front transmission support on frontaxle cross member Studs on frontaxle cross member Front cross member to final drive Drive shafts on frontaxle final drive Diagonal braces on body and frontaxle cross member Tank strap on body Pipe holder on transmission support

Thread M18 M8 M8 x 36 M8 M10 x 90 M10 M10 M8 M10 M8 M12 M8 x 40 M6

Tightening torque Nm (ftlb.) 28 (21) 25 (19) 25 (19) 39 (29) 65 (48) 65 (48) 65 (48) 20 (15) 65 (48) 39 (29) 100 (74) 23 (17) 7 (5.0)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Front wheel drive Z 96.00

148

3 Technical data
5speed Tiptronic transmission A 96.50150 Front wheel drive Z 96.00 top of page

5speed Tiptronic transmission A 96.50150

Type A 96.50150

Code letter

Equipment 5speed

Installed in 911 Turbo (996)

Model year 2001

Note In order to protect 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 engine speed is limited to 4000 rpm in the selector lever positions P and N.

General data Type Ratio Spur gear 1st gear 2nd gear 3rd gear 3 Technical data

Transmission A 96.50150 Fully automatic 5speed planetary gear set (Tiptronic) 0.76 3.59 2.19 1.41 149

einordnung 4th gear 5th gear Reverse gear Final drive Final drive ratio (without spur gear) Filling capacity, rearaxle final drive Automatic section: new filling (with torque converter) Change quantity 1.00 0.83 1.93/3.16 Bevel gear drive 9 : 34 = 3.77 1.2 l approx. 9.0 l approx. 4.5 l

Tightening torques for Tiptronic transmission

Location ATF check screw to ATF pan ATF drain plug on ATF pan ATF pan to transmission housing Cap nut to ATF charging valve ATF charging valve to transmission housing Filler plug for rearaxle oil Drain plug for rearaxle oil Hydraulic control unit on transmission housing Short flanged shaft to differential Cover for final drive on transmission housing Mounting saddle for long flanged shaft to transmission housing Drive shaft on transmission flange Transmission support to body Transmission support to transmission mount Drive shaft to flanged shaft Converter to drive plate Crash support to intermediate case Transmission to intermediate case Collar nut Water hose holder to transmission Plug connection to socket Holder to mounting saddle

Thread M10 M10 M6 M14 x 1.5 M14 x 1.5 M18 x 1.5 M24 x 1.5 M6 M10 x 55 M8 M8 M10 M10 M10 M10 M8 x 20 M8x60 M8x35 24 x 1.5 M6 M4 M6

Tightening torque Nm (ftlb.) 22 (16) 22 (16) 8 (6) 40 (30) 40 (30) 29 (21) 25 (19) 8 (6) 46 (34) 23 (17) 23 (17) 45 (33) 65 (48) 65 (48) 81 (60) 39 (29) 23 (17) 23 (17) 160 (118) 10 (7.5) 2.5 (2.0) 10 (7.5)

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einordnung

Front wheel drive Z 96.00

Type Z 96.00

Code letter

Equipment

Installed in 911 Turbo (996) worldwide

Model year 2001

General data Transmission ratio, final drive (Z2 : Z1 = i) Final drive Filling capacity

Frontaxle final drive Z 96.00 31 : 9 = 3.44 Bevel gear drive without hypoid offset approx. 1.5 l

Frontaxle drive tightening torques

Location Screw plug, oil drainage and oil filling Cover to final drive Longneck tube to final drive Drive shaft to final drive Rear transmission support to transmission mount Rear transmission support to body Front transmission support to frontaxle cross member Studs on frontaxle cross member Front cross member to final drive Front wheel drive Z 96.00

Thread M18 M8 M8 M8 M10 x 90 M10 M10 M8 M10

Tightening torque Nm (ftlb.) 28 (21) 25 (19) 25 (19) 39 (29) 65 (48) 65 (48) 65 (48) 20 (15) 65 (48) 151

einordnung Diagonal braces to body and frontaxle cross member Tank strap to body Pipe holder to transmission support M12 M8 x 40 M6 100 (74) 23 (17) 7 (5)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Frontaxle drive tightening torques

152

4 Removing transport lock (spring strut locking devices) Turbo and GT2
General Removing spring strut locking devices top of page

General
Spring strut locking devices are installed on the front axle of the following new vehicles in order to protect the vehicle during transport (e.g. driving on and off during lorry transport): Turbo RoW (new vehicles) Turbo USA (new vehicles) 911 GT2 (new vehicles) This increases the ground clearance of the vehicle. Tests have demonstrated that spring strut locking devices are not necessary at the rear axle. With the 911 GT2, the spoiler lip is also removed from the front spoiler. Fitting the enclosed front 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 locking devices are not removed, this will seriously impair the handling behaviour and thus the driving safety! The spring strut locking devices must be removed before a test drive and before the vehicle is handed over to the customer! Note Send the removed spring strut locking devices to the Porsche Warranty Test Office in Ludwigsburg! Include the spring strut locking devices with the normal warranty goods consignment!

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Removing spring strut locking devices

Note The wheels need not be removed! 1. Lift the vehicle (wheels at the front axle must be free).

4 Removing transport lock (spring strut locking devices)

Turbo and GT2

153

einordnung 2. Remove spring strut 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

Removing spring strut locking devices

154

4 Lifting the vehicle

Lift the vehicle top of page

Lift the vehicle

CAUTION Danger of material damage if the vehicle is raised incorrectly or if the vehicle is driven incorrectly onto the lifting platform! Lift the vehicle only at the takeup 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 lift and the vehicle! In order to avoid damage to the side members and side member panels, the mounting plates of the platform lift must be raised!

front

rear

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

4 Lifting the vehicle

155

4 Tests/notes for allwheel drive

Balancing wheels on vehicle Power test Brake test Towing manual transmission vehicles Towing Tiptronic vehicles top of page

Balancing wheels on vehicle

When fine balancing wheels on the vehicle, all four wheels must be raised and must be able to turn freely. If a fault occurs in PSM (Porsche Stability Management), read out fault memory before fine balancing. After fine balancing, the fault memory of the PSM control unit must be erased. top of page

Power test
Power tests can only be carried out on 4roller type test stands! top of page

Brake test
Brake tests can only be carried out on rollertype test stands or plate test stands. If no allwheel drive test stand (rollertype test stand) is available, the following limit values must not be exceeded for conventional rollertype test stands: Test speed max. 7.5 km/h Test duration max. 20 seconds. top of page

Towing manual transmission vehicles

If vehicle is towed with raised front or rear axle, the wheels of the raised axle must be able to turn freely. The ignition must be switched off and the shift lever must be in neutral. top of page

Towing Tiptronic vehicles

With engine not running, sufficient lubrication of the transmission is not ensured. Select position N. Switch off ignition. Do not exceed top speed of 50 km/h. Maximum towing distance 50 km. For longer towing distances the vehicle must be raised at the rear axle or transported on a trailer.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

4 Tests/notes for allwheel drive

156

4 Switching off PSM

Note Switching off PSM Switching PSM back on Characteristic features of Tiptronic vehicles (slip upshift) Note The PSM (Porsche Stability Management) is automatically operational/switched on after each engine start!

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Switching off PSM

Press the PSM OFF logo of the rocker switch. The PSM switches off after a short delay. When the PSM is off, the PSM OFF warning light in the instrument panel and the indicator light in the rocker switch are lit. When braking, the vehicle is also stabilised when the PSM is switched off! Onesided wheel spin is also prevented when the PSM is switched off! On Tiptronic vehicles, the function slip upshift is switched off when PSM is switched off! => The PSM should always be switched on for normal driving. In exceptional cases, it can be advantageous to switch off the PSM temporarily: on a loose surface and in deep snow when rocking the vehicle free when using snow chains. top of page

Switching PSM back on

Press the indicator light in the rocker switch. The PSM switches on after a short delay. top of page 4 Switching off PSM 157

einordnung

Characteristic features of Tiptronic vehicles (slip upshift)

When a maximum permissible speed difference between front and rear axle is exceeded, an integrated slip monitoring shifts into the next highest gear. This increases 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 also when the friction coefficent is low as is the case with manual transmission vehicles.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Characteristic features of Tiptronic vehicles (slip upshift)

158

5 Plug location plan

Caution Top of front end Bottom of front end Side of front end Bottom of lower side member and floor Top of lower side member and floor Bottom of rear end Top of 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 plugs provided once more following disassembly or repair work!

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Top of front end

A Rubber grommet hole 20 mm B Rubber grommet hole 30 mm top of page

5 Plug location plan

159

einordnung

Bottom of front end

Plug hole 20 mm

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Side of front end

A Rubber grommet hole 20 mm B Rubber grommet hole 30 mm top of page Bottom of front end 160

einordnung

Bottom of lower side member and floor

A C D E

Rubber grommet hole 20 mm Plug hole 10 mm Plug hole 10 mm Plug hole 15 mm

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Top of lower side member and floor

A Rubber grommet hole 20 mm K Plug hole 30 mm Bottom of lower side member and floor 161

einordnung top of page

Bottom of rear end

A D E F

Rubber grommet hole 20 mm Plug hole 10 mm Plug hole 15 mm Plug hole 20 mm

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Top of rear end

Top of lower side member and floor

162

einordnung A Rubber grommet hole 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

Top of rear end

163

Seam seals
Accessories

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Accessories
Note Due to modifications to the 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 the accessories coated with KTL paint (cathodic dipbath coating).

Seam seals

164

einordnung The seam seal can be painted over when it has reached approx. 70 % hardness (approx. 4 5 h at 20 C, 50 % relative air humidity). (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 causes no damage to the sealing mass surface, the seam seal can be painted.

Front lid

Door

Accessories

165

einordnung

Sliding roof panel

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Sliding roof panel

166

5 Work sequence for accident repair

Work sequence for accident repair Determine scope of damage Expose the area to be repaired Make an economic or technical decision. Should parts be repaired or replaced? Determine the scope of replacement parts and have the parts obtained Repair Replacement Determine the scope of replacement Determine the scope of replacement parts and have the parts parts and have the parts obtained obtained Cover undamaged areas of the vehicle Cover undamaged areas of the vehicle so that they are protected against fire Prepaint 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 damaged areas If necessary, apply filler or body Cut out remaining pieces solder on reshaped areas Fit new parts in, then check the gap dimensions with the accesories fitted Protect spotwelded flanges against corrosion Apply fine filler on repair areas Disconnect battery and observe safety and quality instructions for welding. Weld in new parts Grind visible weld seams flat; if necessary apply body solder or filler If necessary, primer and seal the seam areas If necessary, renew the stone impact protection

5 Work sequence for accident repair

167

einordnung Paint the repaired area If necessary, touch up the undersealing Seal cavities Fit accessories

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

5 Work sequence for accident repair

168

5 Work sequence for determining scope of damaged vehicles involved in an accident

Note Note A body is constructed so that it has deformable zones in the front and rear area. These deformable zones enable absorption of impact energy due to their special construction. The bearing structure in these areas is adapted by a specific cross section reduction to provide optimum energy reduction in the event of an impact. Due to the vehicle dimensions in the side area of the body, deformable zones can not be provided for absorbing energy. The impact energy can only be absorbed to a small extent here through the deformation of doors and columns. This is also the case for the roof area where only the roof seal can absorb impact energy to a very small extent. In these areas, passenger protection is guaranteed by a rigid construction of the passenger compartment. The aim of this design is to absorb the impact energy in defined areas to keep the passenger compartment as free of damage as possible in the event of an accident. If the passenger compartment has been deformed in the event of an accident, extremely large reshaping 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 usually the result of a front and side impact or a rear and side impact. The deformation is not always in the impact area. Due to bearing forces of loads such as running gear, drive line, occupants of the vehicle and load or the body itself, deformation can also occur in the opposite areas. The following work sequence should provide assistance to correctly determine the scope of damage of vehicles damaged in an accident.

Work sequence for determining scope of damaged vehicles involved in an accident Identify impact points on the outer shell or the wheels Remove accessories which limit view of the impact area Check unit holders, running gear parts and steering parts for deformation and cracks Determine scope of damage on the body Identifiable deformations on the body structure No identifiable deformations on the body structure Visual inspection of the structural parts for creasing Check seam joining line on the and bending from the impact starting from the central accessories 5 Diagram Body gap point of vehicle dimensions 5 Work sequence for determining scope of damaged vehicles involved in an accident 169

einordnung Visual inspection of the structural parts on the connection points for gaping plate connections (e.g. entry area on the side member under the rubber seal of the door) Drive vehicle onto 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 measuring system and compare with the specified values. 5 Repair check dimensions Check accessories for paint abrasion (accessories which have been in contact during the impact) Drive vehicle onto 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 measuring system and compare with the specified values. 5 Repair check dimensions Determine scope of any existing damage to vehicle parts 4 If necessary, measure running gear electronically 44 Suspension alignment Decide whether vehicle has to be repaired

Decide whether vehicle is technically repairable

Decide whether vehicle is economically repairable

If necessary, repair vehicle 5 Work sequence for accident repairs

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

5 Work sequence for determining scope of damaged vehicles involved in an accident

170

5 Corrosion protection measures during repairs

Measures for maintaining longterm body protection Prerequisite for ensuring vailidity of the longlife guarantee top of page

Measures for maintaining longterm body protection

Note After repair work, the standard corrosioninhibiting coating should only be restored with the corrosioninhibiting agents approved by the manufacturer. The following points must be observed for body repairs. Always apply welding primer to both sides of the welding flange when resistance spot welding. Prime repair areas from outside. Prime on both sides in the accessible areas. Seal all sheetmetal overlaps, sheetmetal edges, butt joints, weld seams etc. with body sealant. Only apply body sealant to primed sheetmetal parts. Apply singlecoat top coat paint to the inside of the outer sheetmetal shell before welding. See "Paint buildup": 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 longlife undersealing material. Preserve cavities in the repair area with cavity preservation after applying a singlecoat top coat. Check that the standard water drains (plugs) are functioning correctly or clean them after the cavity preservation material has dried.

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Prerequisite for ensuring vailidity of the longlife guarantee

Porsche longlife guarantee conditions All body repair work must be carried out correctly and according to the specific Porsche instructions for sheetmetal, paint and corrosion protection/preservation work. To prevent jeopardising the longlife guarantee, a Paint Condition Report is made out 2 years after delivery of the vehicle. This condition report must be drafted annually be every Official Porsche Centre.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

5 Corrosion protection measures during repairs

171

5 Vehicle identification number

Imprinting new vehicle identification number Materials, tools After replacing the body or the sheetmetal parts in the area of the vehicle identification number (firewall), the original vehicle identification number must be reimprinted onto the new body or the new sheet metal part. The documentation of the imprinted vehicle identification number in the vehicle supplementary document or legally permissible treatment can be obtained from the importer of the respective country. An incorrectly imprinted (stamped) vehicle identification number should be permanently crossed 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 vehicle identification number

1. Spacer for replacing the vehicle identification number The spacer for applying the vehicle identification number is in the front, right firewall. Two sections are intended for use. Section 1 A is the standard spacer. Section 2 B is the spare spacer for a corrected vehicle identification number. 2. Imprinting new vehicle identification number => Materials, tools Note Only imprint vehicle identification number in a KTL (cathodicdip coated) sheetmetal part. 1) The area should be countered when imprinting the vehicle identification number.

5 Vehicle identification number

172

einordnung a. Stamp the vehicle identification number to be replaced into the spacer with an 8 mm number embossing tool and the Porsche star. b. Mask imprinted vehicle identification number. c. Apply exterior paintwork. d. Remove the vehicle identification number mark. e. Paint repair area with clear lacquer. 1) Cathodicdip coating is the primer applied to the sheetmetal parts at the factory top of page

Materials, tools

Item 1

Designation of the special tool Number embossing tool 8 mm DIN 1451, closely spaced lettering Nr.1281 Porsche star Sonderwerkzeug 9693

Remarks Gr. 2.4; Workshop Equipment Manual

Gr. 2.2; Workshop Equipment Manual

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Imprinting new vehicle identification number

173

5 Change identification data plate

After exchanging sheetmetal parts, side section, or doors, a new indentification data plate must be attached. The identification data plate must be ordered from the importer of the respective country. 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 section RoW B Left doors USA/Canada

3. Identification data plate RoW a. Item number b. Vehicle identification number

4. Identification data plate USA a. Item number b. Vehicle identification number

5 Change identification data plate

174

einordnung

5. Identification data plate Canada a. Item number b. Vehicle identification number

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

5 Change identification data plate

175

5 Undersealing
Note Overview diagram, lower front of vehicle Overview diagram, bottom of lower side member and floor Overview diagram, lower rear end Tools and 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 following illustrations. The undersealing must only be applied on primed sheetmetal panels.

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Overview diagram, lower front of vehicle

5 Undersealing

176

einordnung

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

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

Overview diagram, lower front of vehicle

177

einordnung

Overview diagram, lower rear end

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

Tools and materials

Item 1

Special tool designation Recommendation Terostat multifunctional sealant 9320 Sprayable seam and compartment sealant

Remarks Manufacturer: Henkel Teroson GmbH Postfach 10 56 20 69046 Heidelberg www.teroson.com Recommendation Multipress telescopic spray gun For working with Manufacturer: Henkel Terostat 9320 Teroson GmbH Postfach 10 56 20 69046 Heidelberg www.teroson.com

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Overview diagram, lower rear end

178

5 Water drainage plan

Cabriolet

1 2 3 4 5 6 7 8

Water drainage: Drainage panel Water drainage: Drip tray Water drainage: Drainage tube Water drainage: Water channel, side section Water drainage: Evaporator for heating and airconditioning system Water drainage: Tank tray Water drainage: Radiator tank Water drainage: Inner panel of convertible top compartment lid

996630, 996631, 996620, 996621, 996650, 996651

5 Water drainage plan

Cabriolet

179

5 Check dimensions for body repair Cabriolet structure

Structure dimensions for cabriolet

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Structure dimensions for cabriolet

5 Check dimensions for body repair Cabriolet structure

180

einordnung

Note All dimensions are measured on the body shell (with units removed) middle hole or middle screw connection point. The dimensions are measured directly and, therefore, are oblique dimensions. Refer to the relevant vehicle views for the positions of the measuring points. The 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 the mirrorred image on the right side of the vehicle. Note The specified dimensions are used only for an approximate estimation of possible structural damage. Repairs to the vehicle must be done using an alignment system.

Structure dimensions for cabriolet

181

einordnung Measuring point P1L P1R P2L P2R P3L P3R P4L P4R P5L P5R P6R P6L Designation Convertibletop positioning screwed point (thread M6) Convertibletop positioning screwed point (thread M6) Locking screwed point (thread M6) Locking screwed point (thread M6) Convertibletop support/Bpillar Screwed point (thread M8) Convertibletop support/Bpillar Screwed point (thread M8) Convertibletop support/inner front side section Screwed point (thread M8) Convertibletop support/inner front side section Screwed point (thread M8) Convertibletop support/inner rear side section Screwed point (thread M8) Convertibletop support/inner rear side section Screwed point (thread M8) Auxiliary frame (rollover bar) screwed points (M8 thread) Auxiliary frame (rollover bar) screwed points (M8 thread)

Measured path Designation P1 P3 Oblique dimension, convertibletop support, Bpillar P1 P5 Oblique dimension, convertibletop support, front side section P1 P4 Oblique dimension, convertibletop support, rear side section

Dimension A 743.4 mm B 1033.1 mm C 1092.8 mm

996630, 996631, 996620, 996621, 996650, 996651

Structure dimensions for cabriolet

182

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 takeup 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 takeup points can lead to material damage on the vehicle! Lift the vehicle only at the approved takeup 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

einordnung

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Safety instructions for welding

Dangers of injury when welding

DANGER Risk of fatal injury from high voltage during electric welding. Danger of explosion and fire when welding in the area of highly inflammable materials. Irritation to respiratory tracts from toxic zinc oxide emitted when welding galvanized steel! Danger of injury from weld spatters and UV light when welding! Danger of injury from false releases of pyrotechnical safety components! Do not perform welding work in a humid environment or on a wet background; there is a risk of fatal injury from the voltage being conducted through the human body. Persons with heart pacemakers should not perform welding work. Use insulating underlays. Remove highly flammable materials from the work area; if necessary, remove units with fuelcarrying parts and protect work areas in the vehicle that are at risk of catching fire using fireproof covers. Ventilate the work area well. Remove 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 mask. For welding work, always disconnect both terminals on the battery. In the case of welding work in the immediate vicinity of the control modules for pyrotechnical safety systems, remove the control modules before beginning work. In addition, the guidelines of the welding equipment manufacturers and the legal accident prevention regulations and those of the mutual indemnity association (BGV D1) must be observed.

Safety instructions for flying sparks during grinding and welding work
CAUTION Danger of explosion and fire from flying sparks during grinding and welding work! Danger of damage to vehicle parts and other vehicles due to flying sparks! Cover vehicle parts such as battery, fuel system, paintwork, glass and passenger compartment parts with fireproof covers and, if necessary, remove batteries and fuelcarrying components. No other vehicles may be left unprotected in areas used for body repair!

Damage when raising vehicles

184

einordnung

Safety instructions for fuel tank

CAUTION Danger of fire due to fuel tank or fuelcarrying parts heating up during grinding and welding work! When carrying out grinding and welding work near the fuel tank or fuelcarrying parts, make sure that these parts do not heat up! It is recommended to remove endangered parts! Cover the welding area comprehensively with fireproof covers!

Safety instructions for air conditioning

CAUTION Danger of injury due to the filled airconditioning system bursting during welding and soldering work! In the case of extreme heating of filled airconditioning systems, a very strong overpressure may be caused in the system which may lead to an explosion. No welding, soldering or hotair heating may take place on parts of the filled airconditioning system! While drying after painting work, the temperature burden on the vehicle must not exceed two hours at a maximum temperature of 80 C! Make sure that parts of the airconditioning system do not heat up during welding or soldering work on the vehicle!

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Safety instructions for sticking

Safety instructions for Teromix6700 twocomponent adhesive

CAUTION Danger of damage to side section if binding time of adhesive is not observed! The new part must be welded in within 30 minutes!

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Safety instructions for fuel tank

185

einordnung

Safety instructions for installation work

Safety instructions for sharpedged body and unit parts

CAUTION Danger of injury from sharp edges on body and unit parts! Wear protective gloves when working in the area of sharpedged body and unit parts!

Safety instructions for airbag system

CAUTION 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 adjustment work until a waiting period of at least 1 minute has elapsed! The ground strap of the battery must be disconnected during work on the airbag system 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 system! The door lock should be installed only when the actuating lever is in basic position! CAUTION Damage to plug connection lugs during door removal! Damage to lugs when pulling the plug connection out of the Apillar! The locking element at the bottom part of the plug connection must be pulled out before the plug connection is disconnected! CAUTION Damage to the bowden cable when removing door trim panel! Damage by bending the bowden cable at the hook! Pull the hook out of the end piece only after installation in the inner door release! Safety instructions for installation work 186

einordnung CAUTION There is a danger of injury if fingers or hands are trapped by the door window when the comfort function is triggered: lower and raise door window! When carrying out assembly work in the area of the connection piece, the door handle and the door lock, the fuse No. 1 in row D must be removed!

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Safety instructions for corrosion protection

Safety instructions for plug location 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 once more following disassembly or repair work!

Safety instructions for water drains (body)

CAUTION Water drainage hoses can be pushed out or pressed in by blowing them out of the body during cleaning! When cleaning, only blow the water drainage hoses out with light compressedair pressure!

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Safety instructions for door

187

5 General information and quality notes

Measures for maintaining longterm body protection Electronic control modules top of page

Measures for maintaining longterm body protection

Note After repair work, the standard corrosioninhibiting coating should only be restored with the corrosioninhibiting agents approved by the manufacturer. The following points must be observed for body repairs. Always apply welding primer to both sides of the welding flange when resistance spot welding. Prime repair areas from outside. Prime on both sides in the accessible areas. Seal all sheetmetal overlaps, sheetmetal edges, butt joints, weld seams etc. with body sealant. When replacing structurally bonded body parts, proceed according to the information in the respective repair instructions. Only apply body sealant to primed sheetmetal parts. Apply top coat paint to the inside of the outer sheetmetal shell before welding. See "Paint buildup": 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 longlife undersealing material. Preserve cavities in the repair area with cavity preservative after applying a top coat paint. Check that the standard water drains (plugs) function correctly or clean them after the cavity preservation material has dried.

Prerequisite for maintaining the longlife guarantee

All body repair work must be carried out correctly and according to the specific Porsche instructions for sheetmetal, paint and corrosion protection/preservation work. To prevent jeopardising the longlife guarantee, a Paint Condition Report is made out 2 years after delivery of the vehicle. This condition report must be updated annually by every Official Porsche Centre. top of page

Electronic control modules

Note If electronic components, e.g. ABS control unit, have been removed for repair work and are then reused, they must be given a functional check after fitting in accordance with existing specifications.

5 General information and quality notes

188

einordnung

Protection against overvoltage

To protect electronic control units from overvoltage during electric arc welding, the following work regulations must be observed: When welding work is extensive, the electronic control units must be removed. Ensure that there are no electrically insulated parts between the ground connection and the welding point. Remove clamp from negative terminal of battery and cover negative terminal of battery. Connect the ground connection of the electric arc welding equipment as near as possible to 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 electronic control modules after an accident is necessary if at least one of the following conditions is met: The housing is noticeably deformed or damaged. The supporting surface or bracket is deformed (the unit shows no external damage). The plug connection is damaged or corroded by moisture. Functional checks or selfdiagnosis of the unit reveals the fault "Control module faulty".

996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631, 996840, 996841

Protection against overvoltage

189

5 Tools and metalworking tools for body repairs

Note Straightening systems Metalworking tools Note Detailed and additional information about tools and equipment can be found in the "Workshop Equipment" manual.

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Straightening systems
Shown on Celette type

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Metalworking tools

Electrical equipment

5 Tools and metalworking tools for body repairs

190

einordnung

1. Drill 2. Angle grinder, large 3. Angle grinder, small 4. Sander 5. Hotair gun

Mechanical equipment

6 Hole punch 7 Edge setter

Compressedair equipment

Electrical equipment

191

einordnung

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

Compressedair equipment

192

5 Diagram keys to symbols for welding work

Resistance spot welding Inertgas arc welding (MAG procedure) Gas 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

Inertgas arc welding (MAG procedure)

A Plug weld B Stitch weld C Full weld D Intermittent full weld top of page

Gas welding

5 Diagram keys to symbols for welding work

193

einordnung

A Hard soldering

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Gas welding

194

5 Check dimensions for body repair

Floorpan check dimensions top of 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 brackets are measured horizontally.

5 Check dimensions for body repair

195

einordnung Dimension P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21 A B C D E F G H I J K L M N Measuring points P1 P1 P2 P2 P3 P3 P4 P4 P5 P5 P6 P6 P7 P7 P8 P8 P9 P9 P10 P10 P11 P11 P12 P12 P13 P13 P14 P14 P15 P15 P16 P16 P17 P17 P18 P18 P19 P19 P20 P20 P21 P21 P4 P7 P5 P18 P8 P2 P8 P3 P8 P4 P8 P7 P8 P12 P8 P12 P13 P11 P13 P14 P13 P15 P13 P17 P13 P18 P13 P19 Designation Impact absorber / pipe front Bearer side sparewheel well Front axle front, front, low Front axle front, rear, high Rational location hole, side member front Spring strut bracket, front Front axle front, rear Front jacking point for hoist or car jack Transmission support, front Transmission support, centre Transmission support, rear Rear jacking point for hoist or car jack Rear diagonal brace Rear axle, front Rear axle, centre Spring strut bracket, rear Rear axle, rear Rational location hole, side member rear Engine mount location hole outside Engine mount Impact absorber / pipe rear In vehicle's longitudinal direction In vehicle's longitudinal direction Vehicle diagonal dimension Vehicle diagonal dimension Vehicle diagonal dimension Vehicle diagonal dimension Vehicle diagonal dimension In vehicle's longitudinal direction Vehicle diagonal dimension Vehicle diagonal dimension Vehicle diagonal dimension Vehicle diagonal dimension Vehicle diagonal dimension Vehicle diagonal dimension Dimension in mm 8002 7122 6101 731,21 8001 9852 7731 13302 2562 2702 4002 13702 8243 8362 8212 9152 7922 9451 889,2 7802 9602 5072 27951 15252 12792 12792 (12832) 10842 19292 13502 8753 (8633) 10873 (10853) 11593 (11253) 12373 (12093) 13493 (13233) 16293

Measuring point P1 P2 Floorpan check dimensions

Designation Screwed point (M8 thread)

196

einordnung Bearer side sparewheel well screwed point (M8 thread) FA, front screwed point low (thread M12 x 1.5) FA, front screwed point high (thread M14 x 1.5) Rational location hole, side member front Spring strut bracket, front FA, rear screwed point (thread M14 x 1.5) Hoist/car jack front location hole Transmission support, front screwed point (thread M10) Transmission support, centre screwed point (thread M10) Transmission support, rear screwed point (thread M 12 x 1.5) Hoist/car jack rear location hole Diagonal brace front screwed point (thread M10) RA front screwed point (thread M12 x 1.5) RA centre screwed point (thread M12 x 1.5) Spring strut bracket, rear RA rear screwed point (thread M12 x 1.5) Rational location hole, side member rear Engine mount location hole outside Engine mount screwed point Impact absorber / pipe rear screwed point (thread M8)

P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16 P17 P18 P19 P20 P21

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Floorpan check dimensions

197

5 Water drainage plan

A water drainage facility 12 is available on both sides of the vehicle.

1 2 3 4 5

Water drainage: Rear of sliding roof Water drainage: Front of sliding roof Water drainage: Evaporator of heating and airconditioning system Water drainage: Tank tray Water drainage: Radiator tank

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

5 Water drainage plan

198

5 Diagram body gap dimensions

Note Gap dimensions, body front Gap dimensions, body centre Gap dimensions, body rear Gap dimensions, body rear Carrera 4S Diagram Gap dimensions, Cabriolet Note Set gap dimensions on the lids, doors and covers, or accessories in accordance with the gap specifications. Given a clearance 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 wedgeshaped fashion or do not narrow at local points. The given values are guidelines which should be observed as far as possible. The guidelines apply to repair and assembly work. Use star gauges to measure the gap dimensions,No.: 1271, Workshop Equipment Manual, Chapter 2.4

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Gap dimensions, body front

5 Diagram body gap dimensions

199

einordnung

Designation Front cover to front trim Front cover to modular headlight Modular headlight to front trim Modular headlight to wing Wing to front trim Front wing to outer side section Wing to front cover Windscreen to Apillar Windscreen to outer roof panel Filler flap to wing Gap dimensions, body front

Dimension A B C D E F G H J K L M

4+2 4.5 4.5 3.5 0.8 2 1.5 3 0.5 4+1 0.5 1.2 4 0.5 7.5+2.5 1 8.5+1 2 3.5 1

Note mm Cover only lowered (max. 1 mm) mm Determine gap left to right mm mm mm mm Gap is evident mm mm mm mm Determine gap left to right mm mm All the way round 200

einordnung

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Gap dimensions, body centre

Designation Door to front wing Door to outer side section

Dimension A B C D E F

4+2.5 4+1 0.5 1.5 3.5+1

0.5

Note mm Door only lowered (max. 1 mm) mm mm Doors only lowered mm

2 mm Doors only lowered +1 4 0.5 mm Doors only raised 201

Gap dimensions, body centre

einordnung G H J K L M 4+1 0.5 mm Door only raised (max. 1 mm) 1.6 mm Determine regularly all the way round 7 1 mm

Air inlet to outer side section Door window to rear side window Side section to outer roof panel Roof joint strip to outer roof panel Sliding roof panel to outer roof panel

25.3 mm 1 3.2 1 mm 5.5 0.5 mm All the way round, sliding roof panel only lowered at front, only raised at rear (max. 1 mm)

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Gap dimensions, body rear

Gap dimensions, body rear

202

einordnung

Dimension A B Rear trim to outer side section C Tail light to outer side section D E Rear trim to tail light F G Rear lid to rear trim H J K L Gap dimensions, body rear

Designation Side member cover to outer side section

Note 1.4 +0.5 2 3 0.5 3 0.5 2 1 5 2 2+1 2 5 2 2.2+0.5

1.5

mm mm mm mm mm mm mm mm mm

Gap is evident Tail light only lowered Tail light only lowered Rear lid only lowered

5 2 1.8+0.5

mm mm Rear lid only lowered 203

einordnung
1.5

Rear lid to tail light Rear lid to outer side section Rear centre panel to outer side section Rear centre panel to rear lid Rear window to outer roof panel Rear window to rear centre panel Rear window to outer side section

M N O P Q R S T U

4.5 1 4.5 1 4.5 1

mm Tail light only lowered (max. 1 mm) mm Rear lid only lowered (max. 1 mm). determine left to right mm

6+1 2 mm Rear lid only lowered (max. 1 mm) +1 7.3 2 mm 8.5+1 2 8.9 7 6 mm mm Dimension is evident mm mm Determine left to right

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Gap dimensions, body rear

Carrera 4S

Gap dimensions, body rear

Carrera 4S

204

einordnung

Designation Rear trim to outer side section Tail light to outer side section Tail light to middle side section Rear trim to tail light Rear lid to side section Rear lid to rear spoiler Rear lid to spoiler top section Rear centre panel to spoiler top section Gap dimensions, body rear

Dimension A B C D E F M G H I J

3 0.5 3 0.5 2 1 3 0.5 2 1 5 +1 1 2 +1 2 4.5 1 5 2 4.5 1 6 1

Note mm Gap is evident mm mm Tail light only lowered mm mm Tail light only lowered mm Tail light only lowered mm Determine gap left to right mm Rear lid only lowered mm Rear lid only lowered (max. 1 mm) mm Rear lid only lowered (max. 1 mm)

Carrera 4S

205

einordnung Rear lid to spoiler top section K 4.5 1 mm Rear lid only lowered (max. 1 mm). determine seam 7.3+1 2 mm 6 mm 7 mm Determine left to right 4.3 1 mm 1.2 mm Adhesive seam 5.2 1 Only lowered

Rear window to outer roof panel L Rear window to outer side N section O Outer side part to rear centre part P Q Rear centre part to rear lid R

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Diagram Gap dimensions, Cabriolet

Diagram Centre gap dimensions, Cabriolet

Diagram Gap dimensions, Cabriolet

206

einordnung

Designation Cowl panel frame to fender Windscreen to cowl panel frame Door window to rear window Rear side section flap to side trim panel

Dimension A B C D

3.5 to 7.0 1 8.5 +2.5 1 9 1 4 +2.5 1

mm mm mm mm

Note Continuous transition

E Rear side section flap to frame trim panel F for rollover protection system Cowl panel frame to roof frame 1 G

4 +2 3 +2 0.5 7 1

mm mm mm

Rear side section flap raised (max. 0.5 mm), lowered (max. 1.5 mm) Rear side section flap raised (max. 1 mm) Rear side section flap raised (max. 0.3 mm) Roof frame only lowered

Diagram Centre gap dimensions, Cabriolet

207

einordnung

Diagram Gap dimensions, rear Cabriolet

Designation Side part to convertibletop compartment lid

Convertibletop compartment lid to rear lid Convertibletop compartment lid to rear lid

Dimension A B C D E

+1

0.5

mm mm mm mm

to 5 0.5 6.4+1 0.5 6 +1 0.5

+1

Note Continuous seam joining line

Diagram Gap dimensions, rear Cabriolet

208

einordnung

Diagram, gap dimensions, Cabriolet rear Carrera 4S

Designation Side part to convertibletop compartment lid

Convertibletop compartment lid to rear lid Convertibletop compartment lid to spoiler top section

Dimension Note +1 A 5 0.5 mm Continuous seam joining line B to +1 C 5 0.5 mm D 6.4 +1 mm

0.5

6 +1

mm

Diagram, gap dimensions, Cabriolet rear Carrera 4S

209

einordnung

Diagram Gap dimensions, hardtop

Designation Windscreen frame to convertible top

Dimension A B Rear window to rear roof frame (Hardtop) C D Hardtop to convertibletop compartment lid E Hardtop to convertibletop compartment lid F G Roof joint strip to hardtop H Hardtop to side section I

Note 5.5 0.5 4 +1 2 10.4 3 1.5 5.5+2 6.5+2 7.8 4 0.8 1 3+2 mm mm Convertible top only lowered mm mm mm mm mm Tail light only lowered mm Only lowered mm

Diagram Gap dimensions, hardtop

210

einordnung

996420, 996421, 996450, 996451, 996630, 996631, 996430, 996431, 996620, 996621, 996650, 996651

Diagram Gap dimensions, hardtop

211

5 Body parts of highstrength steel

Highstrength steel plates Tailored blanks Baked hardening Straightening body parts Welding work Reshaping Separation points Diagram Body, model year 2002 The following body parts are made of highstrength steel (HS).

1 Bearer side at sparewheel well, left and right 2 Connection bracket inner to side member front inner left and right 3 Side member front inner, left and right 5 Body parts of highstrength steel 212

einordnung 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 A B C Web plate outer side member front outer left and right Side member front outer, left and right Cowl panel frame top, inner Cowl panel frame bottom, outer Cowl panel frame bottom, inner Apillar reinforcement, left and right Side member floor front bottom, left and right Bearer floor front top, left and right Front crash support Closing part front crash support Tunnel reinforcement Seat support, left and right Hinge pillar, left and right Cross member firewall, inner Firewall Apillar reinforcement Side member rear outer, left and right Impact absorber mount Side member rear inner, left and right Web plate Reinforcement cross member firewall, front Reinforcement cross member firewall inner left 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 , B and C possess extremely high tensile strength and are therefore not hotdip galvanized! Body parts 1 to 23 attain their final strength only after the production stage of cathodic immersion painting and drying! The special material properties have effects on body repair. For this reason, only "Original Porsche parts" must be used for repair work!

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Highstrength steel plates

Body parts of highstrength steel contribute to better protection of the passenger compartment and thus increase protection of the passengers. In addition to improved crash safety, these parts also have a positive influence on fatigue strength. In terms of crash behaviour, body parts made from highstrength sheet steel are Highstrength steel plates 213

einordnung characterised by their higher energy absorption. But this also means that higher reshaping force must be applied in reshaping work. Note Only "Original Porsche parts" must be used for repair work!

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Tailored blanks
The indicated body parts are made by welding together plates of differing thicknesses and characteristics and then deepdrawing these parts. In their crash behaviour, these body parts are characterised by their high energy absorption.

top of page Tailored blanks 214

einordnung

Baked hardening
The indicated body parts attain their final strength only under the temperature effects of the production stage of cathodic immersion painting and drying.

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Straightening body parts

Note Only "Original Porsche parts" or sections of "Original Porsche parts" may be used! The body and floor assembly are produced in series from deepdrawn panels. For this reason, accident damage must be reshaped in the same way. Body repairs by 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 Baked hardening 215

einordnung repairs. The separation of damaged body parts after reshaping against the accident direction should not take place until after connection pieces have been straightened. top of page

Welding work
Note The use of the oxyacetylene welding process is not permissible for body parts made of highstrength steel! Test welding must be carried out in the case of resistance spotwelding (RP) of different panel strengths! The body parts made from highstrength steel can be welded using the RP resistance spotwelding or MIG welding processes that are customary in workshops. top of page

Reshaping
Note Only "Original Porsche parts" or sections of "Original Porsche parts" may be 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 repairs by 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. top of page

Separation points
Note Separation points which influence the strength of the body, and thus also the operating and traffic safety of the vehicle, must be carried out according to the specifications of the relevant Technical Manual Body repair! Body reinforcements can be separated or joined together only if this is specified in the method descriptions. Otherwise, a damaged reinforcement must always be replaced with a new one!

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Straightening body parts

216

einordnung

Diagram Body, model year 2002

In the model year 2001 (model care), the following 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 parts (model care) for model year 2002

Diagram Body, model year 2002

217

einordnung

1. Front side members (cross member double connection) 2. Interior door reinforcement (diagonal) 3. Inner lower side 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, 996450, 996451, 996430, 996431, 996840, 996841

Structural body parts (model care) for model year 2002

218

6 Safety notes
Safety instructions for work on car windows Safety instructions for installation work top of page

Safety instructions for work on car windows

Danger of injury when working on car windows

WARNING Danger of cut injuries when removing and installing car windows! Cutting out glued car windows may lead to cut injuries to the skin and the eyes due to flying glass splinters and 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 with the power supply disconnected 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 section and to the label with the vehicle identification number if windscreen is removed incorrectly! When cutting out the windscreen, ensure that the surrounding section and the label with the vehicle identification number are not damaged! Cover painted areas adjacent to the window aperture with adhesive tape. Guide the cutting knife as closely as possible along the edge of the window.

Material damage when inserting the glass into car windows

CAUTION Danger of material damage if specified curing time of adhesive is not observed! The vehicle must not be used until the curing time has elapsed.

6 Safety notes

219

einordnung 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 10C Fixing time: approx. 1 hour

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Safety instructions for installation work

Safety instructions for airbag system

CAUTION Danger of injury due to unintentional activation of airbag units! The ground strap of the battery must be disconnected during work on the airbag system and alignment bench jobs when the body is being repaired! After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar tools may not be started until after a waiting period 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 sliding roof mechanism is damaged if the sliding/tilting roof trim is moved incorrectly! The sliding roof mechanism must not be moved to the "Open" position when the sliding roof panel has been removed! In order to avoid damage to the guides of the sliding roof, the sliding/tilting roof trim (Item 4) must be moved without the use of force!

Safety instructions for rear spoiler

WARNING Danger of injury and danger of damage to the vehicle if handling is modified when adjusting the additional wing! The additional wing must be moved to the lowest position for use in public traffic! Material damage when inserting the glass into car windows 220

einordnung

Safety instructions for the pump unit hydraulic system of the rear spoiler
DANGER Danger of injury/damage during assembly work on the hydraulic system! The hydraulic system 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 contact with skin/eyes.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Safety instructions for the pump unit hydraulic system of the rear spoiler

221

6 General information on installing and removing car windows

Removing glass with cutting wire separator top of page

Removing glass with cutting wire separator

Note The following instructions describe the general procedure for removing car windows with the glass separating tool VAG 1474 B. Information on procedures relating to specific vehicles can be obtained from the instructions in the corresponding chapters in the Technical Manual.

Item A

Designation Source Glass separating tool VAG See Workshop Equipment 1474 B Manual, Chapter 3.5 Cutting thread See Parts Catalogue in Main Group 8

Remarks Contains component set A1A9 and protective film for dashboard

Item A1 A2

Designation Guide rails Cutting tool (wire holder)

Item A6 A7

Designation Filler Steering roller with arm bracket 222

6 General information on installing and removing car windows

einordnung A3 A4 A5 Spooling device Awl Guide rails A8 A9 Handle Square cutting wire

Note It is generally possible to remove the windscreen with the cutting wire and the optional cutting thread contained in the tool set. In contrast to cutting threads, however, the cutting wire has the following disadvantages: Danger of injury when tearing off the cutting wire. Danger of damage to materials on paint surfaces and interior equipment parts. For the reasons outlined above we recommend using the cutting thread. WARNING Danger of cut injuries when removing and installing car windows! Cutting out glued car windows may lead to cut injuries to the skin and the eyes due to flying glass splinters and 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 with the power supply disconnected in order to ensure that the cutter cannot be switched on accidentally. CAUTION Danger of paint damage and damage to surrounding section and to the label with the vehicle identification number if windscreen is removed incorrectly! When cutting out the windscreen, ensure that the surrounding section and the label with the vehicle identification number are not damaged! Cover painted areas adjacent to the window aperture with adhesive tape. 1. Cleaning glass on the inside Note In order to guarantee an optimum fastening intake grip, it is advisable to clean the inside of the glass before removal.

Removing glass with cutting wire separator

223

einordnung

2. Applying protective film to the dashboard a. Select the appropriate film 1 and insert between windscreen and damping mat. Note The film 1 protects the damping mat against damage when removing the glass.

3. Inserting cutting thread into the passenger compartment Note In order to prevent damage, make sure that the vehicle identification 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 the awl A4 from the inside to the outside. c. Pass cutting thread B through the eyelet on the awl A4 . d. Draw cutting thread B into the passenger compartment. e. Pull cutting thread B out of the awl A4 . f. Draw cutting thread B approx. 1 metre into the passenger compartment.

Removing glass with cutting wire separator

224

einordnung

4. Inserting cutting thread into the gap in the glass g. Pull cutting thread B in the direction of the arrow through the gap between the glass and the body. Use filler A6 if necessary. Note The cutting thread should be positioned under the rim as far as possible. The sealing lip must be raised slightly in the upper part of the glass in order to 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.g. wiper motor fastening). To do this, unscrew the fastening screw, wind the cutting thread B around the screw and tighten the fastening screw again.

6. Attaching cutting thread to the spooling device i. Undo clamping screw 3 . j. Insert cutting thread B into the bore on the spooling device A3 . Removing glass with cutting wire separator 225

einordnung k. Attach cutting thread B firmly with the clamping screw 3 .

7. Installing spooling device and deflection rollers on the glass l. Position spooling device A3 diagonally in the centre of the glass. m. Press spooling device A3 with the fastening intakes firmly against the glass. n. Fix fastening intake 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 device p. Release spooling device. q. Release the lower fastening intake on the spooling device. r. Pull cutting thread through onto the other side of the fastening intake. s. Fix fastening intake onto the glass by moving the actuating lever. Removing glass with cutting wire separator 226

einordnung

10. Separating glass as far as P2 t. Position deflection roller in the lower right corner. u. Press deflection roller with fastening intake firmly against the glass. v. Fix fastening intake onto the glass by moving the actuating lever. w. Pass cutting thread over the deflection roller onto the spooling device. x. Separate glass by spooling the cutting thread on the spooling device as far as point P2 . Note The fastening force 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 with fastening intake firmly against the glass. ab. Fix fastening intake onto the glass by moving the actuating lever. ac. Pass cutting thread over the deflection roller onto the spooling device. ad. Separate glass by spooling the cutting thread on the spooling device as far as point P3 . Note The fastening force can be increased by moistening the fastening intake. Removing glass with cutting wire separator 227

einordnung

12. Repositioning spooling device ae. Release spooling device. af. Release the upper fastening intake on the spooling device. ag. Pull cutting thread through onto the other side of the fastening intake. ah. Fix fastening intake onto the glass by moving the actuating lever.

13. Separating glass as far as P4 ai. Position 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 cutting thread over the deflection roller onto the spooling device. am. Separate glass by spooling the cutting thread on the spooling device as far as point P4 using guide rail A1 . Note The fastening force can be increased by moistening the fastening intake.

Removing glass with cutting wire separator

228

einordnung

14. Separating glass as far as P5 an. Release spooling device. ao. Position deflection roller in the lower left corner. ap. Press deflection roller with fastening intake firmly against the glass. aq. Fix fastening intake onto the glass by moving the actuating lever. ar. Pass cutting thread over the deflection roller onto the spooling device. as. Separate glass by spooling the cutting thread on the spooling 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 section from the windscreen. Note If the surrounding section is removed from the windscreen undamaged, it can be reused.

Cutting power when removing glass with cutting thread

Note The power for separating the glass is weaker when the cutting thread is deflected to its maximum point. An angle greater than 90 should be avoided.

Cutting power when removing glass with cutting thread

229

einordnung

High cutting power Unfavourable angle (strong traction required)

Average cutting power Favourable angle (average traction required)

Low cutting power Optimum angle (minimum traction required)

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Cutting power when removing glass with cutting thread

230

6 Overview of exterior colours

Note Exterior paintwork Exterior paintwork Special colours Note As from model year '02, the same colour code will be used for waterbased paints and for conventional paints. solid metallic/pearl

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Exterior paintwork

solid

Colour designation Biarritz white Carrara white Black Black Guards red Speed yellow
1) Waterbased 2) Conventional

Colour code 9A2 9A3 1) B9A 1) 2) 741 1) 747 2) 041 1) 2) 84A 1) 80K 2) 12H 1) 12G 2)
1)

01 X X X X X X X X

02

03

Model year 04 05 06 07

08

09

10

X X X X X

X X X X X

X X X X X

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Exterior paintwork

metallic/pearl

Colour designation Black metallic Basalt black metallic

Colour code 744 746 2) C9Z 1) 2)

1)

01 X X

02

03

Model year 04 05 06 07

08

09

10

X 231

6 Overview of exterior colours

einordnung Arctic silver metallic Lapis blue metallic Rainforest green metallic Orient red metallic Carmona red metallic Zanzibar red pearl effect Meridian metallic Seal grey metallic Atlas grey metallic Midnight blue metallic Lagoon green metallic
1) Waterbased 2) Conventional

92U 1) 92T 2) 3A8 1) 3A9 2) 2A1 1) 2A2 2) 8A3 1) 8A4 2) M3W 1) 2) 1A8 1) 1A9 2) 6A6 1) 6A7 2) 6B4 1) 6B5 2) M7X 1) 2) 39C 1) 37W 2) M6W 1) 2)

X X X X X X X X X X X X X X

X X X X X X X X X X X X X X

X X X X

X X X X

X X X

X X X X X X X

X X X X X X X X

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Special colours

Colour designation Dark blue Fayence yellow Wimbledon green metallic Pine green metallic Violet metallic Cobalt blue metallic Polar silver metallic

Colour code 3C7 347 2) 1C1 1) 2) 2B6 1) 23L 2) 2B4 1) 22E 2) 3AE 1) 39G 2) 3C8 1) 37U 2) 92M 1) 92E 2)
1)

01 X X X X X X X X X X X X

02

03

Model year 04 05 06 07

08

09

10

X X

X X

X X

X X X X

X X X X

X X X X 232

Exterior paintwork

metallic/pearl

einordnung GT silver metallic Slate metallic Midnight blue metallic Zanzibar red pearl effect
1) Waterbased 2) Conventional

M7Z 1) 2) 23F 1) 22D 2) 39C 1) 37W 2) 1A8 1) 1A9 2)

X X X X

X X X X

X X

X X X

X X

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Special colours

233

6 Processing of Porsche 2component window bonding agents

Overview of tools and materials Preparing the adhesive surfaces Combined procedure (handling double cartridge press) top of page

Overview of tools and materials

Item A B

Designation Double cartridge gun VAS 5237 Pipette VAG 1344

Source Remarks See Workshop Equipment Manual, Chapter 3.5 See Workshop Equipment Manual, Chapter 3.5 234

6 Processing of Porsche 2component window bonding agents

einordnung C D H Special electric cutter (fine) VAG 1561 A Flashing knife, Utype 639.031.130.22 2component window bonding agent 000.043.300.94 See Workshop Equipment Manual, Chapter 3.5 Contains set components H1H8

Item H1 H2 H3 H4

Designation Cleaning solution Primer Activator Swab

Item H5 H6 H7 H8

Designation Cartridge, component A Cartridge, component B Mixing nozzle Processing nozzle

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Preparing the adhesive surfaces

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 With preliminary coat coat Cut back adhesive bead Cleaner Clean rim (ceramic layer) Clean preliminary layer Activator Primer Activator Activate adhesive bead Prime rim (ceramic layer) Activate preliminary (only necessary if car is idle for a long period) layer Apply adhesive Install glass

Prepare the window flange for installation Old flange (old paint job)

New flange (new paint job)

Overview of tools and materials

235

einordnung Cut back adhesive bead Cleaner Clean flange surface Primer Prime rim (ceramic layer)

Activator Activate adhesive bead (only necessary if car is idle for a long period) Apply adhesive Install glass

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Combined procedure (handling double cartridge press)

CAUTION Observe 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!

1. Preparing cartridge components A and B H5, H6 a. Pierce the membrane in the nozzle connection of components A and B (aluminium cartridge) H5 with a screwdriver and extend the opening. Remove flanged cover on end of cartridge.

Preparing the adhesive surfaces

236

einordnung 2. Screwing on processing nozzle H8 b. Screw processing nozzle H8 onto the mixing nozzle H7 .

3. Screwing on mixing nozzle H7 c. Screw both cartridges onto the mixing nozzle.

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 arrow allow the pressure piston to move out slowly until the adhesive is visible in the processing pipe.

Combined procedure (handling double cartridge press)

237

einordnung 6. Affixing car window Note The bonding material has an open time of 15 min , which means that the bonding material must be applied and 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 processing.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Combined procedure (handling double cartridge press)

238

7 Special notes for the care of softlook paint surfaces

Caution Light soiling (e.g. dust) Heavy soiling (e.g. oily, greasy dirt) CAUTION Damage to the softlook paint coat if the cleaning agents or solvents available as accessories for cleaning the vehicle interior are used. This also applies to the use of plastic polish 999.901.021.41 from the Porsche care set. The contents of these agents etch the paint coat (paint swells, rubberlike texture). Consequently, the paint coat can fall off the substratum when a mechanical load is applied. Furthermore, the surface may shine brightly after using the cleaning agents. The following procedure is recommended for the care or cleaning of softlook paint surfaces on the basis of laboratory tests.

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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 Soft household sponge Cleaning fluid Clear water Water with small amount of commercially available washingup liquid added Interior window cleaner (from Porsche care set) Note Observe cleaning instructions, wipe down with clear water if necessary Cleaning procedure

Soft, lintfree cloth

Gentle wiping movements, do not apply pressure

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Heavy soiling (e.g. oily, greasy dirt)

It is possible to clean heavy soiling by selecting an option from the following cleaning tools and cleaning fluids: Cleaning tools Soft household sponge Cleaning fluid Water with small amount of commercially available washingup liquid added Cleaning procedure

7 Special notes for the care of softlook paint surfaces

Gentle wiping movements, do not apply pressure

239

einordnung Interior window cleaner (from Porsche care set) Note Observe cleaning instructions, wipe down with clear water if necessary Solvent naphtha Note: Use solvent naphtha only, other solvents are not permissible!

Soft, lintfree cloth

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Heavy soiling (e.g. oily, greasy dirt)

240

8 Air conditioning
Technical data for the airconditioning system top of page

Technical data for the airconditioning system

Note When installing the refrigerant lines, the screw connections and the Orings must be wetted with refrigerant oil! The refrigerant oil must be disposed of as specialcategory waste!

Compressor type 7 SB 16 Refrigerant quantity Refrigerant oil in the compressor

900 g Refrigerant R 134a 195 15 cm3 ND 8

Hexagonhead bolts on: Expansion valve Compressor Refrigerant line Oil filler plug Fluid tank Flange connections of the refrigerant lines

Thread M6 M5 M8 M8 M10 M6 M8

Tightening torque in Nm (ftlb.) 9 (6.5) 6 (4.5) 23 (17) 23 (17) 26 to 36 (19 to 27) 6 14 (10.5)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

8 Air conditioning

241

9 Work instructions after disconnecting the battery

Effect of disconnection or total discharge of the battery on electrical systems in the vehicle, subsequent measures Control module memories Supply voltage fault entry Test drive after connecting the battery 2470 DME control module 6452 Power windows 90 25 Instrument cluster 9030 Clock 9023 Fuel level display 9120 Radio 9110 PCM top of page

Effect of disconnection or total discharge of the battery on electrical systems in the vehicle, subsequent measures
Note In order to avoid triggering the alarm siren (installed on right next to the battery) of vehicles with M 536, the battery must be disconnected with 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 engine! Whenever possible, use jump leads with overvoltage protection! Always disconnect both battery terminals before carrying out welding work on the vehicle! Wiring harness plugs of control modules or other electronic components must be connected or disconnected with the ignition off. Exception: vehicles with the additional equipment M 536 (alarm siren with tilt sensor)!

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Control module memories

Problem Values and faults stored in the control modules can be deleted if the battery is disconnected or completely 9 Work instructions after disconnecting the battery

Remedy If possible, all fault memories should be checked and, if necessary, printed 242

einordnung discharged. out before the battery is disconnected.

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Supply voltage fault entry

Problem The entry "supply voltage" could be stored in various control modules if the battery has been completely discharged.

Remedy Delete the "supply voltage" entry from the control modules in question.

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Test drive after connecting the battery

Note The fault memories of all vehicle control modules should be read out again after the test drive!

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2470 DME control module

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 After disconnection of the power supply, the idle speed might change or fluctuate briefly until the throttle adjusting unit (ME 7.8) is readapted. The mixture adaptation is also lost.

Remedy After the battery is connected. With the DME ME 7.8, it is necessary to carry out a learning and adaptation routine as described below: 1. Switch the ignition on for 1 minute without starting the engine. Do not actuate accelerator pedal. 2. Switch off ignition for at least 10 seconds.

Control module memories

243

einordnung This completes the adaptation of the throttle adjusting unit.

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6452 Power windows

Problem Remedy The limit positions of the power windows are deleted from Manually close each power window as the control module when the battery is disconnected and far as it will go, then press the rocker connected. switch for closing the window again. The limit position of the respective power window is now stored in the control module again.

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90 25 Instrument 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 disconnected!

Problem The time is deleted when the power supply is disconnected.

Remedy Enter the current time again.

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9023 Fuel level display

Problem If the power supply is interrupted by a discharged or disconnected battery with the tank containing less than 19 l, the calculated value for the range on remaining fuel in the 2470 DME control module

Remedy Fill the tank; then the fuel level sensor is in operating range and its display precision is 244

einordnung instrument cluster will be incorrect or deleted. If the tank contains less than 19 l, it is possible that the fuel level warning light is no longer activated. 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 an incorrect value. This may lead to the vehicle breaking down. guaranteed.

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9120 Radio

Problem Remedy The radio reverts to the Code function when the battery 1. Input the radio code. is disconnected and is thus no longer ready for operation. 2. If the code card is unavailable, the radio code can also be read from the DME control module (under "Vehicle data"). 3. It is also possible to gain this code from the Porsche IPAS.

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9110 PCM

Problem The PCM reverts to the Code input function when the battery is disconnected and is thus no longer ready for operation. When the power supply is disconnected, the builtin GPS receiver loses the socalled almanac containing the satellite orbital paths. The date and time are deleted when the battery is disconnected. Radio stations stored by the customer are no longer displayed. If the telephone card was inserted and the telephone was ready for operation, the telephone is subsequently disabled.

Remedy 1. Input the PCM code. If the code card is unavailable, the PCM code can also be read from the DME control module (under "Vehicle data"). 2. It is also possible to gain this code 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 are also adopted once the GPS almanac has been loaded; it may be necessary to change over to summer time (daylightsaving time). This time is transferred to the instrument cluster. If the time is then manually changed by means of the instrument cluster, this time is adopted by the PCM and synchronised with GPS time. 5. The stored stations are displayed again when station buttons 1 to 6 are pressed. 245

9023 Fuel level display

einordnung 6. 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

9110 PCM

246

30 Clutch: checking fluid levels

General Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment and luggage compartment Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment Checking Pentosin CHF 11 S hydraulic fluid in the luggage compartment top of page

General
CAUTION Danger of material damage if the wrong fluid is used! Fill Pentosin CHF 11 S only into both supply tanks! Pentosin CHF 11 S can be ordered with the following part 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 instead of the servo pump for the steering (996 naturally aspirated engine) for this purpose. Both systems share one supply tank (expansion tank). This tank A is located in the engine compartment.

In addition, a second supply tank for the clutch actuating circuit is available in the luggage compartment under the cover A . top of page

Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment and luggage compartment
Note

30 Clutch: checking fluid levels

247

einordnung The supply tank for the power steering and the clutch booster circuit is located in the engine compartment! The second supply tank for the clutch actuating circuit is secured under a cover in the luggage compartment!

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Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment

Note The dipstick located on the reservoir cap has the "Cold marking" (approx. 20 C engine temperature) on one side and the "Hot max" symbol on the other side.

Pentosin tank in the engine compartment Check the fluid level (Pentosin CHF 11 S) with the engine stationary and cold (approx. 20 C). CAUTION Danger of damage to property if too much Pentosin CHF 11 S is filled or if it comes in contact with the coolant hoses when topping up or filling in! Observe the following 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 reservoir! Fluid 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 IMMEDIATELY! Replace visibly swollen coolant hoses! 1. Start engine and run it at idle speed for approx. 20 seconds. Switch off engine. 2. Open the engine cover. 3. Open reservoir cap. 4. Wipe off the dipstick. Close and then reopen the cap. The fluid level should 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 warmedup condition, the fluid level must not exceed the "Hot max" mark! Checking Pentosin CHF 11 S hydraulic fluid in the enginecompartment and luggage compartment 248

einordnung top of page

Checking Pentosin CHF 11 S hydraulic fluid in the luggage compartment

WARNING Danger of damage and injury if the wrong fluid is filled in after the caps have been changed! If fluid is being filled into several tanks in the luggage compartment (brake fluid / water / Pentosin), carry out these filling procedures in sequence (always screw off just one cap) so that the caps of the 3 tanks are not interchanged! This prevents any chance of another person filling in the wrong fluids at a later stage! Note On righthand drive vehicles, the supply tank is located in the area of the brake fluid reservoir/control module for automatic headlight beam adjustment (ALWR)! The fluid level on the transparent supply tank should always lie between the Min. and Max. marking! Hold the supply tank by hand (counter) to undo and tighten the cap. Pentosin CHF 11 S hydraulic fluid should not be topped up until the fluid level is at the lower marking!

This tank 2 supplies the clutch actuating circuit with Pentosin.

1. Remove cover A .

Checking Pentosin CHF 11 S hydraulic fluid in the enginecompartment

249

einordnung

Front tank 1 Brake fluid reservoir / black cap with yellow marking. 2 Pentosin reservoir for clutch actuation / green cap 3 Washer fluid container / blue cap.

2. If the fluid level in the transparent container 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. Counter the container when doing this.

4. Install cover A .

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Checking Pentosin CHF 11 S hydraulic fluid in the luggagecompartment

250

40 Tightening torques for front axle

Cross member/side member (1 component) Diagonal brace Control arm Spring strut/wheel carrier Frontaxle final drive/drive shaft (Turbo) Stabilizer Steering Wheel fastening top of page

Cross member/side member (1 component)

Location Cross member/side member on body (front and rear) Corner plate on side member Corner plate on body Corner plate on body (with diagonal arm and side member)

Thread M14 x 1.5 M10 x 1.5 M12 x 1.5 M14 x 1.5

Tightening torque Nm (ftlb.) 160 (118) 65 (48) 100 (74) 160 (118)

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Diagonal brace

Location Diagonal brace on body and side member

Thread M12 x 1.5

Tightening torque Nm (ftlb.) 100 (74)

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Control arm

Location Control arm on side member Control arm on diagonal arm Control arm on wheel carrier (Ball joint)

Thread M12 x 1.5 M14 x 1.5 M12 x 1.5

Tightening torque Nm (ftlb.) 120 (89) 160 (118) 75 (56)

40 Tightening torques for front axle

251

einordnung 911 GT2 Bssic camber setting on 2part control arm M8 27 (20)

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Spring strut/wheel carrier

Location Spring strut to wheel carrier (shockabsorber tube clamp) Turbo 911 GT2 Spring seat clamp (Turbo) Springstrut mount to body Turbo 911 GT2 Springstrut mount to piston rod (Turbo and 911 GT2) 911 GT2 Stabilizer mating bearing to spring strut (lock nut) 911 GT2 Height adjustment on spring strut (lock nut) Brake cover plate to wheel carrier Brake disc on wheel hub Brake caliper to wheel carrier * Speed sensor on wheel carrier Combination coupling to wheel carrier Retainer plate for wheel bearing to wheel carrier Wheel hub to wheel carrier
1) *

Thread

Tightening torque Nm (ftlb.)

M12 x 1.5 M12 x 1.5 M6 M8 M10 M14 x 1.5 M52 x 1.5 M52 x 1.5 M6 M6 M12 x 1.5 M6 M6 M8 M22 x 1.5

100 (74) 85 (63) 10 (7.5) 33 (24) 35 (26) 80 (59) 50 (37) 50 (37) 10 (7.5) 10 (7.5) 85 (63) * 1) 10 (7.5) 10 (7.5) 37 (27) 460 (340)

Replace screws at front and rear axle whenever they have been removed.

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Frontaxle final drive/drive shaft (Turbo)

Location Thread Frontaxle drive shaft to final drive M8 Frontaxle drive shaft on wheel hub M22 x 1.5 Rear frontaxle transmission support to transmission bearing M10

Tightening torque Nm (ftlb.) 39 (29) 460 (340) 65 (48)

Control arm

252

einordnung Rear frontaxle transmission support to body Front frontaxle transmission support to frontaxle cross member Stud to frontaxle cross member Frontaxle transmission support at front to final drive Tank strap to body M10 M10 M8 M10 M8 65 65 (48) 20 (15) 65 (48) 23 (17)

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Stabilizer

Location Stabilizer to side member Stabilizer mount to stabilizer Stabilizer mount to spring strut (Turbo and 911 GT2) 911 GT2 Stabilizer mating bearing to spring strut (lock nut)

Thread M10 x 1.5 M10 M10 M52 x 1.5

Tightening torque Nm (ftlb.) 65 (48) 46 (34) 46 (34) 50 (37)

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Steering

Location (Unlisted values in Repair Group 48!) Track rod (ball joint pin) on steering arm Universal joint (steering shaft) at steering gear ** Steering gear on cross member ***
1) **

Thread M12 x 1.5 M8 M10 x 1.5

Tightening torque Nm (ftlb.) 75 (56) 23 (17) ** 1) 65 (48)*** 2)

2) ***

Replace fit bolt whenever it has been removed. Replace fastening screws whenever they have been removed.

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Wheel fastening

Location Wheel to wheel hub ****

1) ****

Thread M14 x 1.5

Tightening torque Nm (ftlb.) 130 (96)**** 1)

Thinly grease thread, shank and under head (between screw head bearing surface and spherical cap ring) of the wheel bolts with Optimoly TA (aluminium paste). Do not grease bearing surface of the spherical cap Frontaxle final drive/drive shaft (Turbo) 253

einordnung facing the wheel. If heavily contaminated, clean bolts first with a lintfree cloth.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Wheel fastening

254

42 Tightening torques for rear axle

Carrier side section/cross member Axle strut Wheel carrier Spring strut Drive shaft/stabilizer Unit mount top of page

Carrier side section/cross member

Location Carrier side section to body Studs for carrier side section to body only screwin torque Cross member at rear to carrier side section Cross member at front to carrier side section Brake hose holder to carrier side section Diagonal brace to body to cross member to carrier side section (collar nut)

Thread 12 x 1.5 M12 x 1.5 M12 x 1.5 M10 x 1.5 M6 M10 x 1.5 M12 x 1.5 M10 x 1.5

Tightening torque Nm (ftlb.) 110 (81) 46 (34) 110 (81) 65 (48) 10 (7.5) 65 (48) 110 (81) 23 (17)

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Axle strut

Location Control arm 2 (toe control arm) to wheel carrier to cross member (toe eccentric) Control arm (lower control arm) to carrier side section (camber eccentric) to wheel carrier Diagonal brace to cross arm on carrier side section Control arm 3 and control arm 4 (upper control arms) to carrier side section to wheel carrier 42 Tightening torques for rear axle

Thread M12 x 1.5 M12 x 1.5 M12 x 1.5 M12 x 1.5 M14 x 1.5 M14 x 1.5 M12 x 1.5 M12 x 1.5

Tightening torque Nm (ftlb.) 75 (56) 100 (74) 100 (74) 75 (56) 160 (118) 180 (133) 110 (81) 110 (81) 255

einordnung

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Wheel carrier

Location Wheel bearing to wheel carrier (lid) Speed sensor to wheel carrier Brake cover plate to wheel carrier Brake disc to wheel hub Brake caliper to wheel carrier * Holder for combination wire to wheel carrier Wheel to wheel hub **
1) *

Thread M8 M6 M6 M6 M12 x 1.5 M6 M14 x 1.5

Tightening torque Nm (ftlb.) 37 (29) 10 (7.5) 10 (7.5) 10 (7.5) 85 (63)* 1) 10 (7.5) 130 (96)** 2)

Replace screws at front and rear axle whenever they have been removed. Thinly grease thread, shank and under head (between screw head bearing surface and spherical cap ring) of the wheel bolts with Optimoly TA (aluminium paste). Do not grease bearing surface of the spherical cap facing the wheel. If heavily contaminated, clean bolts first with a lintfree cloth.
2) **

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Spring strut

Location Spring strut to body Turbo 911 GT2 Spring strut to wheel carrier Shock absorber to mount (piston rod) Turbo 911 GT2 911 GT2 Stabilizer mating bearing to spring strut (lock nut) 911 GT2 Height adjustment on spring strut (lock nut)
1) ***

Thread M10 M10 / 10. M12 x 1.5 M12 x 1.5 M12 x 1.5 M52 x 1.5 M52 x 1.5

Tightening torque Nm (ftlb.) 46 (34) 46 (34)*** 1) 110 (81) 58 (43) 60 (44) 50 (37) 50 (37)

GT2 with rollover bar: Carry out a test drive after performing assembly work on the rollover bar/spring support on the body and then retighten the M10 fastening nuts (three per side) to the same torque! top of page

Axle strut

256

einordnung

Drive shaft/stabilizer

Location Drive shaft to transmission to wheel hub Stabilizer to carrier side section Stabilizer mount to stabilizer and spring strut Turbo 911 GT2 911 GT2 Stabilizer mating bearing to spring strut (lock nut)

Thread M10 M22 x 1.5 M8 M10 M10 / 10. M52 x 1.5

Tightening torque Nm (ftlb.) 81 (60) 460 (340) 23 (17) 46 (34) 65 (48) 50 (37)

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Unit mount

Location Engine mount to body Engine carrier to engine Engine mount to engine carrier Transmission carrier to intermediate carrier Intermediate carrier to body Longitudinal support to transmission carrier Longitudinal support to body

Thread M8 M10 M12 x 1.5 M10 M10 M10 M10

Tightening torque Nm (ftlb.) 23 (17) 65 (48) 85 (63) 65 (48) 65 (48) 65 (48) 65 (48)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Drive shaft/stabilizer

257

44 Conversion table for wheel alignment values

Minutes in decimal degrees top of page

Minutes in decimal degrees

The wheel alignment values are specified in degrees and minutes in the Technical Manual (division in 60 units)! In countries in which the decimal degree is widely used, the electronic wheel alignment testers can be converted from degrees/minutes (division in 60 units) to decimal degrees (division in 100 units) by presseing a key (special function)! This function is standard for the electronic wheel alignment testers approved by Porsche. Using the conversion table, minutes (') can be converted into decimal degrees and decimal degrees into minutes (')! To do this, read out the required values with the help of the coordinates!

min (') 0 10 20 30 40 50 60

1 0.017 0.183 0.350 0.517 0.683 0.850

2 0.033 0.200 0.367 0.533 0.700 0.867

0.167 0.333 0.500 0.667 0.833 1.000

4 degrees () 0.050 0.067 0.217 0.233 0.383 0.400 0.550 0.567 0.717 0.733 0.883 0.900

5 0.083 0.250 0.417 0.583 0.750 0.917

6 0.100 0.267 0.433 0.600 0.767 0.933

7 0.117 0.283 0.450 0.617 0.783 0.950

8 0.133 0.300 0.467 0.633 0.800 0.967

9 0.150 0.317 0.483 0.650 0.817 0.983

Conversion from minutes to decimal degrees (examples)

Example 1: Toe 17 min (17') = 0.283 decimal degrees according to table. Procedure for this: The imaginary line starting at the top of the 7 mins column moving downwards and the line starting on the left in the 10 mins row moving right meet at point/column 0.283. Example 2: Camber 1 25' (1 degree and 25 min) = 1.417 decimal degrees. This is the result from the table (1 degree or 60 mins) = 1.000 + 0.417 (25 min).

Conversion from decimal degrees to minutes (examples)

Example 1: Toe 0.350 decimal degree = 21 min (21'). The decimal value (0.350) is searched for in the table. The coordinates are subsequently formed from this point/value. Line to the left = 20' and line upwards = 1' (amounts to 20' + 1'). Example 2: Camber 1.683 decimal degrees = 1 41' (1 degree and 41 min). This is attained as follows: Divide the value in 1,000 = 1 degree (1) and search for the remaining value 0.683 in the table. Then 44 Conversion table for wheel alignment values 258

einordnung form the 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

Conversion from decimal degrees to minutes (examples)

259

44 Adjusting values for suspension alignment Turbo and GT2

Vehicle height Wheel alignment values top of page

Vehicle height
Note The following values relate to the empty weight, i.e., full fuel tank, vehicle with spare wheel/collapsible wheel (not GT2) and tools, but without driver and without additional weight. Turbo and GT2 (M002 and M003) up until model year 2004 are delivered with just one running gear tuning. As of model year 2004, running gear X73 (20 mm tiefer) is also available as an option.

Vehicle height Frontaxle height with 18inch wheels [mm]

Turbo USA

Turbo RoW

Turbo X73 (20 mm lower) 128 10

GT2

118 + 5 (118 to 123) From road contact surface to lower edge of hexagonhead bolt (a/f 18) of the tensionstrut screw connection to the body. Rearaxle height with 18inch wheels [mm]

158 10

138 10

133 + 5 (133 to 138) From wheel contact surface to the locating bore in the rearaxle side section (between toe and camber eccentrics).

163 10

153 10

133 10

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Wheel alignment values

WARNING Warning only applies to vehicles with PSM (only 911 Turbo)! 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! Calibrate steering angle sensor with wheels in straightahead position with the Porsche System Tester 2!

44 Adjusting values for suspension alignment Turbo and GT2

260

einordnung The steering angle sensor actual value must be checked after a suspension alignment where no changes were made to the wheel alignment values! Note The following values relate to the empty weight, i.e., full fuel tank, vehicle with spare wheel/collapsible wheel (not GT2) and tools, but without driver and without additional weight. A caster adjustment is normally not necessary and is therefore not present. The toedifference angle value is also influenced by the vehicle height! For this reason the measured result must be evaluated accordingly! No action is necessary in the case of small deviations from the toedifference 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 lower) + 5' 5' + 5' 5' + 5' 5' 1 20' 30' 1 50' 30' 1 50' 30'

GT2

Front axle Toe unpressed (total) Toe difference angle at 20 lock

+ 8' 2' 1 50' 30' 1 5' 10' 8 30' 40'

Camber (with wheels in straightahead position) max. difference, left to right Caster max. difference, left to right Rear axle Toe per wheel max. difference, left to right Camber max. difference, left to right

0 15' 20' 8 30' 40'

30' 15' 20' 8 30' 40'

45' 15' 20' 8 30' 40'

+ 10' 5' 10'

+ 10' 5' 10'

+ 10' 5' 10'

+ 13' 2' 5' 1 50' 5' 10'

1 25' 15' 1 25' 15' 1 40' 15' 15' 15' 15'

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Wheel alignment values

261

44 Alignment card Turbo

Porsche measurement of running gear Customer: Street: Place: Telephone: Rep. Order No.: Vehicle Ident No.: Licence number: Date of first registration: Odometer reading: km/miles Measurement made by: Date / signature: Vehicle: 911 Turbo (996) Model: Measurement prerequisite (vehicle weight): Empty weight as in DIN 70020. This includes: full fuel tank, vehicle with spare wheel and tools. Reason 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 Nominal values/ (max. Difference, left/right ) Vehicle height: Front (mm) Rear (mm) Rear axle: Camber Toe left/right left/right left/right left/right total Driveaxle angle Front axle: Caster Outgoing measurement

+ 10' 5' / (max.10' ) + 20' 10' 0 00' 10' 8 30' / (max.40' )

left/right

Toedifference angle left right Camber left/right Toe left/right total

+ 3' 3' + 5' 5'

Since mainly electronic wheelalignment testers in conjunction with printers are used, a specimen alignment card is rarely required nowadays. In order for measured results to be documented in individual cases, however, a copy of the alignment card shown above can be used. 44 Alignment card Turbo 262

einordnung Note In practice this means that alignment cards cannot be ordered! The alignment cards can be used for all 911 Turbo (996), USA and RoW! 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 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 incoming measurement (actual status) and enter the values in the alignment card. 5. After adjustments (if these were necessary), enter the actual values in the column Outgoing measurement.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

44 Alignment card Turbo

263

44 Suspension alignment, complete

Vehicle height/wheel load Wheelalignment corrections General procedure for suspension alignment Vehicle height (vehicle height check) Rear axle Front axle There are few differences between suspension alignment on the new 911 Turbo (996) and suspension alignment procedures on the 911 Carrera (996). This involves the vehicle height adjustment, the wheelload difference from left to right, special tools and corrections to wheel alignment. Modified quickclamping holders are required for the 911 Turbo (996) (to fasten the measuredvalue pickups on the wheels). The quickclamping holders present can be retrofitted by replacing the clamping units on the left and right. Supplier: Messrs. Beissbarth. These converted quickclamping holders can also be used retroactively for the other Porsche models. The order number for the new clamping units will be included in the Workshop Equipment Manual.

Note Observe the changed tightening torque when using the insert (tool A )!

Designation of the special Item tool Explanation A Insert for Used to tighten the lock nut(s) at the front track bar(s) to the specified tightening torque torque. It can also be used for loosening. The prescribed lock nut tightening torque of wrench 50 Nm (37 ftlb.) corresponds to a setting on the torque wrench of approx. 35 Nm (26 9625 ftlb.). 44 Suspension alignment, complete 264

einordnung B Insert for Used to tighten the lock nuts of the camber and toe eccentrics at the rear axle to the torque specified tightening torque. It can also be used for loosening. wrench 9626 Torque Commercially available; use in combination with tools A and B. wrench covering the range between 35 Nm (26 ftlb.) and 85 Nm (63 ftlb.)

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Vehicle height/wheel load

Note There are few differences between suspension alignment on the new 911 Turbo and suspension alignment procedures on the 911 Carrera (996)! As with the 911 Carrera (996) models, there is no adjustment facility for changing the vehicle height! This applies to both the front and the rear axles! Since the vehicle height cannot be adjusted, it is not possible to adjust (fine adjustment) the wheelload difference between 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 changing the vehicle height but for compensating for differences in coilspring load groups. Because of the different equipment versions (additional equipment), a greater wheelload difference between the left and right is permissible than previously was the case in Porsche suspension alignment for the 911 Carrera (996) (over 20 kg is possible). This is partly the result of heavier components compared with standard equipment and partly results from additional components that are asymmetrically arranged. top of page

Wheelalignment corrections

Rear axle
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! Vehicle height/wheel load 265

einordnung Calibrate steering angle sensor with wheels in straightahead 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 wheel alignment values! Note Similar to the 911 Carrera models (996), the kinematic toein is not adjustable! Camber and toe can be adjusted via eccentrics!

Front axle
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! Calibrate steering angle sensor with wheels in straightahead 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 wheel alignment values! Note The caster is not adjustable! After adjusting the toe, the lock nuts on the track rods must be tightened to the prescribed tightening torque of 50 Nm (37 ftlb.)! The steering angle sensor must be calibrated if the previous wheel alignment values (on rear and/or front axle) were changed! => Steering angle sensor

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General procedure for suspension alignment

Note Carry out suspension alignment with an optical or electronic wheel alignment tester! The measurement procedures should be taken from the operating instructions for the wheel alignment tester involved! In order to exclude erroneous measurements, the following preconditions must be met before alignment and Rear axle 266

einordnung the following points should be given special attention: Empty weight of vehicle in accordance with DIN 70020, i.e. car ready for the road, with full fuel tank, spare wheel (collapsible wheel) and tools. Balljoint and wheelbearing play in order (wheelbearing play cannot be adjusted). Tyre pressure in accordance with regulations, fairly uniform tyre tread. Quickclamping holder for the 911 Turbo with adapter (for the measuredvalue pickups) correctly secured to the wheels. Receiving surfaces for the quickclamping holder on the wheels and the adapter surfaces must be clean and flat. Always check the levelling surface on the wheels precisely in particular before fitting the quickclamping holders. Strictly comply with maintenance intervals for measuring equipment and measuring platform. If the levelling of the measuring platform or of the measuring area is done inhouse, levelling equipment is required. A hose level is inadequate! Skilled handling of measuring equipment and measuring platform. Sliding plates with transverse motion (rotary motion) at the rear axle are advisable. Observe the Technical Literature of PAG, the manufacturer of the measuring equipment and the manufacturer of the measuring platform. Do not treat measured values as a whole, but very critically in regard to driving dynamics, highspeed strength of the tyres, tyre wear and cost/benefit effects (time required for correction of insubstantial deviations). The toe values are of decisive significance for driving dynamics and tyre wear. If the vehicle is measured front and rear, check and adjust the wheel alignment values at the rear axle first. Camber values at the front axle apply for the straightahead position of the wheels. Steering wheel and steering gear in centre position when toe is being adjusted. Before wheel alignment values are adjusted at front and rear axles, it is recommended that the vehicle height be checked at the DIN empty weight. Conclusions can then be drawn about wheel alignment values in the event of any suspension alignment that becomes necessary later.

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Vehicle height (vehicle height check)

General
Note The vehicle height at front and rear axle is not adjustable!

Preliminary work
1. For the height check, place the vehicle on a level surface or on the measuring platform (ready to drive, with a full tank, spare wheel and tools). 2. Compress vehicle at front and rear by approximately 25 mm 23 times and allow it to spring back freely. General procedure for suspension alignment 267

einordnung

Front axle

Measure from road contact surface to the lower edge of the hexagonhead bolt of the tensionstrut screw connection on the body!

Rear axle

Measure from wheel contact surface to the locating bore in the rearaxle side section (between toe and camber eccentrics)!

Wheel alignment
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! Calibrate steering angle sensor with wheels in straightahead 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 wheel alignment values! Note Only check or adjust wheelalignment values when prescribed preconditions are met!

Front axle

268

einordnung If the vehicle is measured front and rear, check and adjust the rear axle first! After adjustment, tighten the appropriate screwed connections with the prescribed tightening torque! The steering angle sensor must be calibrated if the previous wheel alignment values (on rear and/or front axle) were changed! => Steering angle sensor

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Rear axle
1. Prepare vehicle for checking and/or adjustment of wheel alignment values. 2. Place front wheels on rotary table and rear wheels on rotary / sliding plates. 3. Compress vehicle at front and rear by approximately 25 mm 23 times and allow it to spring 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! Calibrate steering angle sensor with wheels in straightahead 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 wheel alignment values! Note Use insert for torque wrench 9626 in combination with a torque wrench to loosen and tighten the lock nuts of the toe and camber eccentrics.

Prescribed tightening torque of the lock nut(s) = 100 Nm (74 ftlb.)! Adjusting value on the torque wrench (in contrast to earlier specifications) is also 100 Nm (74 ftlb.)!

Wheel alignment

269

einordnung

After loosening the lock nut, turn eccentric B appropriately.

Adjusting toe
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! Calibrate steering angle sensor with wheels in straightahead 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 wheel alignment values! Note Use insert for torque wrench 9626 in combination with a torque wrench to loosen and tighten the lock nuts of the toe and camber eccentrics.

Prescribed tightening torque of the lock nut(s) = 100 Nm (74 ftlb.)! Adjusting value on the torque wrench (in contrast to earlier specifications) is also 100 Nm (74 ftlb.)!

Adjusting camber

270

einordnung

After loosening the lock nut, turn eccentric A appropriately. top of page

Front axle

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! Calibrate steering angle sensor with wheels in straightahead 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 wheel alignment values! The camber is adjusted by moving the spring strut transversely.

For this purpose, loosen the three outer fastening nuts on the springstrut mount and, to move the spring strut, remove the covering cap on the piston rod.

Adjusting caster
The caster is not adjustable.

Adjusting toe

271

einordnung

Adjusting toe
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! Calibrate steering angle sensor with wheels in straightahead 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 wheel alignment values! Note The steering angle sensor must be calibrated if the previous wheel alignment values (on rear and/or front axle) were changed! => Steering angle sensor Preliminary work: 1. Check whether the steering wheel is displaced with respect to the steering gear. 2. To do this, centre the steering gear as described below. 3. Turn wheels to the straightahead position. 4. Then readjust the front wheel alignment, if necessary, until pin No. 2 in driver 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 underside within the recess of lug No. 4. This locks the steering gear in the centre position. After installation of a new steering gear, the lower part of the pin is sheared off (at the desired breaking point No. 3 ) by turning the steering wheel. The upper part of the pin remains in the driver.

If necessary, reposition the steering wheel. When doing this, seek the best position. WARNING A triggering of the airbag (malfunction in the airbag system) caused by improper work on airbag components cannot be ruled out! In the case of such a malfunction, an unsuitable steering wheel holder could cause injury or damage! Use only steering wheel holders which do not project into the area of the airbag unit! Observe safety regulations when working with airbag vehicles! 69 Passenger protection 5. Clamp steering wheel in centre position with steering wheel holder. Note Adjusting toe 272

einordnung Use only steering wheel holders which do not project into the area of the airbag unit!

6. If necessary, shorten the guide rod A at top (arrow) .

7. Then adjust toe at hexagon 2 of the track rod(s) after loosening the lock nut(s) 1 . The steering angle sensor must subsequently be calibrated by PSM! 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! Calibrate steering angle sensor with wheels in straightahead 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 wheel alignment values! Note In order to tighten the tie rod lock nut(s) to the prescribed tightening torque, use an insert for torque wrench 9625 in conjunction with a torque wrench!

The prescribed lock nut tightening torque of 50 Nm (37 ftlb.) corresponds to a setting on the torque wrench of approx. 35 Nm (26 ftlb.)! Adjusting toe 273

einordnung

Toedifference angle
The toedifference angle is not adjustable.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Toedifference angle

274

44 Wheel rims and tires

Tire condition / tire pressure Tire pressure of cold tires (approx. 20 C) Overview of tires and wheels (series) top of page

Tire condition / tire pressure

WARNING Danger of injury and damage to property as a result of modified handling behavior if tires are used which do not correspond to Porschespecific requirements! The stated air pressures are minimum pressures and must never be fallen below, since in addition to the unfavorable driving performance, 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 in the sidewall (ply breakage)! Note Valve caps protect the valve from dust and dirt and therefore from leaks! Always screw caps tight and replace any missing caps!

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Tire pressure of cold tires (approx. 20 C)

911 Turbo
18inch wheels, summer and winter tires front 2.5 bar overpressure rear 3.0 bar overpressure Collapsible wheel front/rear 2.5 bar overpressure for 16 inch 2.8 bar overpressure for 17 inch

911 GT2 (M002/M003)

Note 44 Wheel rims and tires 275

einordnung 911 GT2 M002 = road version 911 GT2 M003 = Club Sport version 18inch wheels, summer and winter tires front 2.2 bar overpressure rear 2.7 bar overpressure Collapsible wheel not present

Spare wheel/collapsible wheel not available! However there is a tire repair kit in the luggage compartment which can be used to repair the damaged tire in the event of damage! For repairs in the event of damage, observe without fail the safety and operating instructions => Repair procedure!

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Overview of tires and wheels (series)

Front axle Turbo 225/40 ZR 18 on 8J x 18 ET 50 GT2 235/40 ZR 18 on 8.5J x 18 ET 40 Rear axle 295/30 ZR 18 on 11J x 18 ET 45 315/30 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 replacing summer tires, pay close attention to the tire specification number! The specification characters N1, N2, N3 or N0 distinguish the summer tires specially authorised by Porsche from other models of the same tire type and size! Note When mounting the wheel on the vehicle, observe the mounting specifications of the wheel bolts => Removing and installing the wheel Turbo and GT2!

Notes on mounting tires

When fitting tires, the direction of rotation and the inner and outer sides should be noted!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

911 GT2 (M002/M003)

276

44 Tyres
Mounting instructions Balancing weights Navigation system Wheel storage Tyre age top of page

Mounting instructions

General

Note

Always use new valves when changing tyres! Steel valves (part no. 993.361.073.00) 1 are used for 18inch Turbo II wheels and rubber valves 2 for 18inch TurboLook II wheels. Steel valve assembly 443519 Removing and installing valve (steel valve). When fitting tyres, the direction of rotation and the inner and outer sides should be noted! Use only TIP TOP Universal, order No. 593 0601 (3.5 kg bucket) or Contifix as the mounting paste! When mounting 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 the bead edge has to perform the sealing function, air can escape when the vehicle is driven aggressively. When mounting the tyre beads, use only the prescribed tyre mounting pastes. The following can occur if an unsuitable mounting paste is used: twisting of the tyre on the rim, fracture of the bead core during mounting, damage to the rim surface by aggressive substances. If Contifix is used, apply sparingly to the tyre beads (due to risk of the tyre turning on the wheel). If possible, the vehicle should not be driven for 24 hours after tyre mounting or matching. Note

44 Tyres

277

einordnung Customers should be informed that the full performance of new or newly mounted tyres is achieved only after a distance of 100 to 200 km (60 to 120 miles) has been driven. Extreme driving manoeuvres (acceleration, braking) should be avoided. The absolute limit on how far the tyre can turn on the wheel must be regarded as 20 mm. An optimum balancing result will be worsened in this case. Mark the relative positions of the tyre and wheel for reference. In order to optimise smoothness of rolling, it is expedient and necessary in individual cases to mount the tyre in a favourable position with respect to the wheel (matching).

Uncontrolled matching
Turning the tyre on the wheel by 90 or 180 if necessary in order to achieve an acceptable value with regard to rolling smoothness (true running, imbalance and distribution of balance weights).

Controlled matching
With a balancing machine with matching program. In most cases, this produces an even better result with regard to the rolling smoothness (true running, imbalance and distribution of the balance weights) than can be achieved with uncontrolled matching.

Fitting
Maximum permissible radial runout and lateral runout 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. After mounting the tubeless tyres, inflate them without valve insert to approximately 4.0 bar gauge pressure in order to ensure that they are seated properly on the wheel. At the latest when the pressure reaches 4.0 bar, the tyre beads must pop out of the deep bed and over the hump of the wheel shoulder in order to avoid fractures of the bead core. If necessary, interrupt the process and coat all necessary surfaces with lubricant (tyre mounting paste) again. Then repeat the process. Screw in the valve insert and set the prescribed tyre pressure. If new tyres are to be mounted or the tyres of one axle are to be replaced, tyres of the same make and with the same specification code must always be used on each of the two axles. If tyres are replaced on one axle only, the different tread depth than on the other axle can cause a noticeable change in the familiar handling. This is especially the case if new tyres are mounted on the rear axle. This effect decreases with increasing tyre mileage. Note If a tyre is damaged and it cannot be determined with absolute certainty that there is no ply damage with all of its consequences or if the tyre was thermally or mechanically overloaded due to a loss of pressure or other prior damage, we recommend replacement of the tyre in question for safety reasons!

General

278

einordnung When replacing a tyre on an axle, make sure that the tread depth of the new tyre does not differ from that of the other tyre by more than 30 %! Repairs on ZR tyres are impermissible, as is the use of inner tubes in tubeless tyres! When replacing summer tyres, pay close attention to the tyre specification number! The overview of summer and winter tyres is included in Technical Information (TI), Group 4. The specification code N1, N2, N3 or N0 distinguishes summer tyres expressly approved by Porsche from other versions of the same tyre type and size. top of page

Balancing weights
Type of balancing weights: Adhesive weights as used previously (no special version necessary). Also refer to the spare parts catalogue.

Affix both weights on the inner side (arrows). Note Observe program selection and operating instructions of the balancing machine.

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Navigation system
After a wheel change, the full locating accuracy is attained only after a journey of approx. 50 km (if possible on the motorway and at a speed > 60km/h). Additionally, high slip of the wheels (e.g. wheel spin) can result in temporary incorrect positioning. top of page

Wheel storage
Tyres must be stored in a cool, dry and dark room with adequate ventilation. They must never come into contact with fuel, oil, grease or chemicals. Complete wheels can be stacked for storage. It is advisable to increase the tyre pressure by 0.4 bar. If the tyres are not mounted on wheels, store them in vertical position. Tyres stored in vertical position should be turned every two weeks in order to prevent excessive flattening. If the tyres are stacked in horizontal position, they will become severely deformed and cannot be seated in the rim flange easily when they are mounted. Fitting 279

einordnung Optimum conditions for proper storage of the complete wheels are provided by the Original Porsche storage stand (trolley), part number 000.044.000.38. Tyres age due to physical and chemical processes, which can impair their function. If they are stored for an extended period, they will harden and become brittle faster than do tyres that are in continual use. Hairline ageing cracks can occur on older 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 even the spare wheel! The age of the tyre can be determined via the manufacturer's code, which is listed behind the DOT code on the tyre sidewall. The date of manufacture (the last four digits) is located at the end of the code. Example DOT DM CP 05 Y 2200 22 = production week 00 = production year 2000

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Wheel storage

280

44 Checking disc wheels

Checking the radial and lateral runout top of page

Checking the radial and lateral runout

Note Straightening and welding work on light alloy wheels is not permissible! Maximum permissible radial runout and lateral runout 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 the tyre (turn the tyre on the rim) if necessary. Note

Use a tyre measuring gauge tyres.

e.g. V.A.G. 1435

to measure wheels without tyres and wheels with

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

44 Checking disc wheels

281

44 Tyre mounting
Note Tools Notes on removing/mounting tyres Removal Fitting Note The mounting machine described here is particularly suitable for the tyre combinations used on the 911 Turbo (996). All parts in contact with the wheel and the tyres are made of plastic. No large point load for wheel and tyres.

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Tools

Item A B C

Designation of the special tool Holdingdown device, commercially available Assembly aid Adhesive weight remover

Explanation To hold down the tyre bead Commercially available; refer to Workshop Equipment Manual, Chapter 2.5 Commercially available

44 Tyre mounting

282

einordnung D Mounting lever commercially available

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Notes on removing/mounting tyres

Note When fitting tyres, the direction of rotation and the inner and outer sides should be noted! Use only TIP TOP Universal, order No. 593 0601 (3.5 kg bucket) or Contifix as the mounting paste. Ensure that no damage (scoring, soiling) is caused to the assembly head of the fitting machine during fitting. Such damage may result in paint 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 order to prevent any paint damage during fitting. The mounting lever can also be covered with adhesive tape in order to avoid damaging the area around the spokes during removal.

The valve must always be replaced when changing a tyre. Steel valves 1 are used for 18inch Turbo II wheels and rubber valves 2 for 18inch TurboLook II wheels. Check the wheel for damage. top of page

Removal
1. Clamp wheel.

Tools

283

einordnung

2. When pushing off the tyre, ensure that the bead pressoff tool is set to the exact inch graduation. If this is not the case, the rim flange may be damaged by the pressoff rollers. 3. The wheel must be turned anticlockwise when pressing the tyre off the rim. Otherwise, excessive forces occur on the fastening bolts of the machine which can lead to bolt breakage. The tyre beads can be pressed off at the same time or individually. 4. Before removing the tyre, coat the tyre beads with mounting paste to facilitate removal. Note The 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 mounting lever is pushed into the deep bed underneath the first tyre bead, and then guided over the assembly shoe and pushed down. 6. Lift the tyre bead out of the rim bed by turning the wheel to the right. 7. Position the assembly aid for the second tyre bead. Pull the tyre upwards and push it into the rim bed underneath the second tyre bead using the mounting lever. Make sure that the mounting lever is guided correctly (see Point 5). Turn the wheel to the right and remove the tyre. top of page

Fitting

Note

Removal

284

einordnung Do not use commercially available steel valves! The Porsche valves (part No. 993.361.073.00) are shorter; dimension X . Dimension X is 43 mm for the Porsche version! 1. Free the wheel from the abraded rubber particles and check for damage.

2. A new valve must always be fitted. Steel valves 1 are used for 18inch Turbo II wheels and rubber valves 2 for 18inch TurboLook II wheels. 3. Coat the wheel and tyre with tyre mounting paste TIP TOP Universal, order No. 593 0601 or Contifix. 4. Place the tyre in the correct position on the wheel. Push in mounting arm and position 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 bead, the mounting arm should be positioned opposite to the valve. This prevents damage to the valve. 7. Press the second tyre bead onto the wheel as flat as possible and guide through the assembly head.

8. Insert first holdingdown device and position the second holdingdown device offset by 90 to 120. Fit tyre bead in deep bed by turning to the right. 9. Fill tyre with compressed air. At approx. 4.0 bar, the beads should pop over the hump. Coat the tyre beads with mounting paste again if necessary so that they can pop over easily and gently.

Fitting

285

einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Fitting

286

44 Balancing/optimising wheels
General Balancing/optimising wheels Balancing weights top of page

General
Excessive wheel imbalance not only produces vibrations and causes the steering wheel to shake, but also results in increased wear on various parts of the running gear. Even if the wheels are correctly balanced, excessive geometry errors (radial and axial runout) and misshapen tyres, e.g. accumulations of material at one point of the tyre structure (spring action of tyre changes as the tyre rolls), can cause rolling and steering imbalance. Note Achieving a good result requires utmost care, observance of the instructions and procedure, and attempting to eliminate even the very last gram of imbalance. Recommendations / prerequisites Wheel suspension elements must be in good technical order. The wheels must be clean and without foreign objects in the tyre. Use a tyre measuring gauge, e.g. V.A.G 1435, to check axial and lateral runout values on wheels without flat spots. Values 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 the tyre (i.e. to mount it in a favourable position with respect to the wheel). Tips and mounting instructions, also about tyre mounting paste under => Tyres. If the rims (wheels without tyres) are true but the complete wheels have large axial and radial runout values (due to ply breakage or other damage), tyre replacement may be necessary. Balance used wheels only after they have been warmed up by driving, otherwise flat spots will simulate imbalance. Never perform matching in the case of flat spots. Correct tyre pressure is an important prerequisite. Place the balancing weights at the prescribed position. Refer to => Balancing weights for information about putting on the balancing weights.

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Balancing/optimising wheels
The entire process is subdivided into four operations. 1. Mounting the tyre on the rim. 2. Stationary balancing of the wheel (eliminating the static and dynamic imbalance) with optimisation of the rolling smoothness. 3. 44 Balancing/optimising wheels 287

einordnung Mounting the wheel on the vehicle. 4. Electronic fine balancing (static balancing) of the wheel on the vehicle after stationary balancing. Required only in exceptional cases.

Further to 1: Mounting the tyre on the rim

Remove rubber residues and driedon tyre paste from the rim, especially from the rim bead and the hump. Examine rim for damage; remove old balancing weights. Use the prescribed tyre mounting paste (only TIP TOP Universal, order No. 593 0601, 3.5 kg bucket, or Contifix) so that the tyre does not turn on the rim the first time the car is driven, thereby destroying all of the careful work. If the tyre turns by as little as 20 mm with respect to the rim, this can worsen an optimum balancing result. Mount tyre on the rim. When doing so, it is expedient and necessary in individual cases to mount the tyre in a favourable position with respect to the wheel (matching). Controlled or uncontrolled matching. Uncontrolled matching: Turning the tyre on the wheel by 90 or 180 if necessary in order to achieve an acceptable value with regard to rolling smoothness (true running, imbalance and distribution of balance weights). Controlled matching: With a balancing machine with matching program. In most cases, this produces an even better result with regard to the rolling smoothness (true running, imbalance and distribution of the balance weights) 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 hump of the wheel shoulder in order to avoid fractures of the bead core. If necessary, interrupt the process and generously coat all necessary surfaces with lubricant (tyre mounting paste). Then repeat the process. Check the fit of the tyre on the rim by means of the bead centring line. Set the prescribed tyre pressure => Wheel rims and tires.

Further to 2: Stationary balancing with optimisation of the rolling smoothness

Clamp wheel on stationary balancing machine. Observe the operating instructions of the balancing machine; occasionally adjust the machine if necessary. The support surfaces of the wheel on the balancing flange (levelling surface) and the centring surface must be clean. Centre (clamp) the wheel from the inside with centring clamping device refer to Workshop Equipment Manual, Chapter 3. This centring clamping device fits on all wheel balancing machines approved by Porsche. Check radial and axial runout during the 1st measuring run. Values less than 1.0 mm better around 0.5 mm are desirable. Consider the size of the measured balancing weights and their distribution on the inner and outer planes (inner and outer rim flanges) critically. A uniform distribution with low values (e.g. 25/30 g) means that the tyre was mounted correctly and the quality of the tyre and rim is good. Balancing/optimising wheels 288

einordnung A value of 80/80 g should not be exceeded. A greatly different distribution, e.g. 30/70 g is very unfavourable; this usually indicates incorrect mounting. Problem wheels of this kind often have pronounced radial and axial runout values. This can be remedied by matching (use correct mounting paste). Improvement is possible with uncontrolled matching (manual); significant improvement is possible in almost all cases with rolling smoothness optimisation program (controlled matching). The tyre pressure must not be less than 1.5 bar overpressure during balancing. Permissible residual imbalance less than 3 g, or max. 3 g per plane.

Further to 3: Mounting the wheel on the vehicle

Note Never use an impact bolter! Observe grease specification and information on the twopiece wheel bolt! This is described in the section describing wheel removal and installation (mounting wheel on the vehicle) => Removing and installing the wheel Turbo and GT2! Mount wheel with suitable commercially available tools. If necessary, mark the position of the wheel on the wheel hub before removing the wheel. Use a piece of adhesive tape to mark the wheel and the wheel hub. This will preserve any optimum balancing result previously achieved by means of fine balancing (finish balancers), even after the wheel is remounted. Screw in wheel bolts by hand and then tighten evenly. Start at the top when tightening. Always observe the specified tightening torque of 130 Nm (96 ftlb.). Prescribed tyre pressure.

Further to 4: Electronic fine balancing

For electronic fine balancing of the wheels on the vehicle, refer to the operating instructions from the equipment manufacturer for information about handling the equipment. When performing fine balancing on all wheels, start with the front axle (4a). Due to the allwheel drive, all four wheels must be raised and must be able to turn freely. Fine balancing of the front wheels to correct torsional vibrations of the steering wheel at approx. 120 km/h. Fine balancing of the rear wheels to correct vibration at 180 km/h and speeds greater than 230 km/h. The following applies to both the front axle and rear axle: the measuredvalue pickups must always stand on a firm surface, the measuring stand support must be located as close to the wheel as possible, doors and lids must be closed and the vehicle must not be touched during the measuring operation, ensure that the lifting equipment used (jack, platform lift) does not touch the vehicle.

Further to 2: Stationary balancing with optimisation of the rollingsmoothness

289

einordnung Affix balancing weights on the outer plane (uniform procedure / could also be distributed or affixed on the inner plane). Under no circumstance remove the weights affixed during stationary balancing. Mark the balancing weight required by electronic fine balancing using a prick punch in order to distinguish it. Read out and erase the PSM fault memory after fine balancing.

Further to 4a: Fine balancing of the front wheels

Note Due to the allwheel drive, all four wheels must be raised and must be able to turn freely. Ensure that the takeup fork of the measuring support does not damage any parts! Position measuring support at the front axle on the right and left. Before the first measuring run, recheck to ensure that slipping from the measuring support is not possible! Centre the sensitivity control. Carry out a measuring run. Affix balancing weight if necessary. Then perform a check run. If the result is unacceptable (precondition: the work was performed properly), calibrate the finish balancer. This means that the sensitivity control must be adapted to the actual situation. If the balancing result is still not quite right even after calibration (for example, 5 g), change the balancing weight according to the balance correction table (balance correction schematic) and thereby eliminate the residual imbalance.

Further to 4b: Fine balancing of the rear wheels

Note Due to the allwheel drive, all four wheels must be raised and must be able to turn freely. Do not damage any parts with the takeup fork of the measuring support! Position measuring support at the rear axle on the right and left. Before the first measuring run, recheck to ensure that slipping from the measuring support is not possible! Set the sensitivity control to 3...3.5 (depending on the equipment version). This corresponds to approx. 1/3 of the max. sensitivity. Perform measuring run at a speed of 130 km/h or 1,150 to 1,200 rpm (wheel revolutions) in the highest gear. Affix the corresponding balancing weight. Perform a check run. Calibrate the finish balancer if the balancing result is unsatisfactory. This means that the sensitivity control must be adapted to the actual conditions. Then (in the case of a good balancing result) slowly increase the speed to 190 km/h and carefully observe at what speed vibration can be felt at the steering wheel and/or seat again (mainly at 175 +/ 5 km/h). Maintain this speed and rebalance the wheels in the same way as at 130 km/h. Do not affix any new weights; instead, improve the wheel running smoothess by changing the existing weights according to the balance correction schematic.

Further to 4: Electronic fine balancing

290

einordnung The imbalance values shown here in this speed range are not real values. They are actually max. 1/4 to 1/3 of the indicated values. The subjective impression in the vehicle is the decisive criterion here. The balancing process is complete only when no more vibrations caused by imbalance are perceptible! top of page

Balancing weights
Balancing weights: Adhesive weights as used previously (no special version necessary). Also refer to the spare parts catalogue.

Affix both weights on the inner side. Note Observe program selection and operating instructions of the balancing machine.

Affixing the adhesive weights

Note Remove the protective film only immediately prior to sticking on the weight, as prolonged 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 strip of adhesive tape until the correct position is determined). Prepare bonding surface on the rim. The bonding surface must be perfectly clean and free of grease. Remove protective paper from the bonding surface of the weight and press the weight firmly into place. The adhesive weight must be in contact uniformly over the entire surface. Check to ensure that the balancing weight is seated firmly. It must not be possible to detach the weight that was just stuck onto the rim by the application of a shear load at right angles to the longitudinal axis of the weight.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Further to 4b: Fine balancing of the rear wheels

291

45 ABS/PSM 5.7 check with Porsche System Tester 2

Test with Porsche System Tester 2 top of page

Test with Porsche System Tester 2

Note

If work has been done on the hydraulic unit, the speed sensors and the cable harness or if the hydraulic unit is replaced, a system check (functional check) must be performed with the Porsche System Tester 2! This is the case, for example, after accident repairs! This prevents any confusion of electrical or hydraulic lines and ensures faultless operation of the system! If certain brake lines are replaced, e.g. at the intermediate piece in the frontleft wheel housing, a system check or a swap test (swap test 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 indication during operation (when no assembly work was carried out beforehand), diagnosis and troubleshooting are also carried out with the Porsche System Tester 2! To do this, select the PSM system and read out the fault memory there! The fault can then be localized using the appropriate menus (Drive links/Actual values)! The Porsche System Tester 2 is connected to the diagnositic socket in the front left footwell in the same way as for the 911 Carrera (996)! Entry takes place through the ABS system (automatic status change after PSM)!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

45 ABS/PSM 5.7 check with Porsche System Tester 2

292

46 Checking brake light switch setting

Brake light switch setting Checking brake light switch setting Adjusting switch if pedal travel is too small top of page

Brake light switch setting

The switch travel of the brake light switch is designed so that the brake light lights up before braking pressure builds up. The switches are selfadjusting and are mounted in a bayonet lock in the pedal block by turning them through 90. By way of its selfadjustment function, the switch compensates for the tolerances in the pedals during initial assembly. Observe following note! Note However, if the switch is "overpressed" during work 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 vehicles with cruise control, the cruise control can be deactivated as a result of vehicle vibrations under certain circumstances. The switch must be readjusted after any work in which the brake pedal is moved out of its "normal" position (for example, work on the pedals or on the brake unit)!

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Checking brake light switch setting

The pedal must move a perceptible distance of approx. 5 to 10 mm before the brake light lights up (stop light switch 1 ).

Check (make sure) that the brake light lights up before the pedal meets perceptible resistance or before brake pressure builds up.

46 Checking brake light switch setting

293

einordnung top of page

Adjusting switch if pedal travel is too small

There are two possibilities to adjust the switch if the pedal travel to the switching point is too small.

1st possibility:
1. Press the brake pedal and pull out the switch plunger. 2. Release the pedal. 3. Check adjustment.

2nd possibility:
Note A playfree fit of the switch is no longer ensured after it has been installed and removed several times. The switch must be replaced by a new switch as soon as it perceptibly "wobbles" in its receiver. When installing 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. Release switch by turning it 90 and pull it out of the installation opening. 2. Pull operating plunger out of the switch as far as it will go. 3. Reinstall the switch.

Adjusting switch if pedal travel is too large

1. Press pedal and press plunger into the switch by one notch (audible click). The pedal travel to the switching point then decreases by approx. 3 4 mm. 2. Check adjustment again.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Checking brake light switch setting

294

46 Tightening torques for mechanical brake

Location Brake caliper * to front and rear axles Brake disc to wheel hub (front and rear axles) Brake cover plate to front and rear axles Speed sensor to front and rear axles Brake unit on body (aluminium interm. part) Brake unit support on body Parking brake console to body Bracket for hydraulic unit on body Hydraulic unit on holder Booster pump for PSM on holder Booster pump for PSM on body at front Wheel to wheel hub **
1) *

Thread M12 x 1.5 M6 M6 M6 M8 M8 M8 M6 M8 M6 M6 M14 x 1.5

Tightening torque Nm (ftlb.) 85 (63)* 1) 10 (7.5) 10 (7.5) 10 (7.5) 23 (17) 23 (17) 23 (17) 10 (7.5) 12 (9) 7 (5) 4 (3) 130** 2)

Replace the brake caliper fastening screws on the front and rear axles every time they are removed. Thinly grease thread, shank and under head (between screw head bearing surface and spherical cap ring) of the wheel bolts with Optimoly TA (aluminium paste). Do not grease bearing surface of the spherical cap facing the wheel. If heavily contaminated, clean bolts first with a lintfree cloth.
2) **

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

46 Tightening torques for mechanical brake

295

46 Technical data/Brake wear limit Turbo

Technical data Turbo with cast iron brake discs Wear limit technical data Turbo with cast iron brake discs top of page

Technical data Turbo with cast iron brake discs

Designation Operating brake (foot brake) with cast iron brake discs (standard brake)

Notes, dimensions Wear limit Hydraulic dualcircuit brake system with frontaxle / rearaxle brake circuit division. Vacuum brake booster, internally ventilated and perforated cast iron brake discs with fourpiston monobloc fixed caliper at front and rear axles. The brake calipers are painted red for visual differentiation. PSM* 1) (Porsche Stability Management) standard. 10 inch 3.85 25.4 mm 25.4 mm 18/18 mm EBV ** 2)

Brake booster (vacuum) Boost ratio Brake master cylinder

front rear Stroke

Brake proportioning control ** Brake discs Effective brake discs front rear front rear front rear front rear

330 mm 330 mm 267.8 mm 271.2 mm 2 x 44 + 2 x 36 mm 2 x 30 + 2 x 28 mm 314 cm2 254 cm2 568 cm2

Piston in brake caliper

Brake pad area Total brake pad area

1) *

Porsche Stability Management (PSM) standard with ABS, Traction Control (TC), ABD, MSR (engine drag torque control), FZR (vehicle regulator) and EBV (electronic brake distributor). Passive switching 46 Technical data/Brake wear limit Turbo 296

einordnung possibility for TC, FZR and MSR. 2) ** EBV = electronic brake distributor (brake proportioning control). As a result, no screwin brake proportioning valves are required! top of page

Wear limit technical data Turbo with cast iron brake discs
Depending on the wear of cast iron brake discs, two condition criteria can make replacement necessary: 1. Cracking in the holed (perforated) brake disc friction plates is in an advanced state. 2. Brake disc minimum thickness is not attained due to wear (material erosion due to friction). Designation Pad thickness Note, dimensions approx. 12.0 mm approx. 12.0 mm 34 mm 28 mm 32.6 mm* 1) 26.6 mm* 1) 32.0 mm 26.0 mm 0.006 mm 0.02 mm 0.03 mm 0.03 mm 0.06 mm approx. 1 mm Drum brake acting mechanically on both rear wheels 180 mm 181 mm 25 mm 4.5 mm 2 mm Wear limit 2 mm 2 mm

front rear front rear front rear front rear

Brake disc thickness, new

Minimum brake disc thickness after machining* 1) Brake disc wear limit

Peaktovalley surface roughness of the brake disc after machining, max. Thickness tolerance of the brake discs, max. Lateral runout of the brake disc, max. Lateral runout of the wheel hub, max. Lateral runout of the brake disc when installed, max. Pushrod play (measured at the brake pedal plate) Parking brake (handbrake) Parking brake drum Brake shoe width Brake pad thickness
1) *

The brake disc must only be reworked symmetrically, i.e. from both sides evenly.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Technical data Turbo with cast iron brake discs

297

46 Checking the thickness of the disc brake pads Turbo and GT2
Caution WARNING Braking effect impaired if the brake pads are exchanged too late! Braking effect impaired if the brake discs are exchanged too late! Danger of injury and damage to 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 wear is indicated by the warning light, the warning contact (sender including wire and plug 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 the core of the wire is worn! However, if only the plastic part of the warning contact is worn, there is no need to replace it! CAUTION Vehicles with PCCB (Porsche Ceramic Composite Brake): Danger of material damage during wheel removal/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) are located in the luggage compartment!

46 Checking the thickness of the disc brake pads Turbo and GT2

298

einordnung

1. To check the brake pads, remove the wheels. Screw the 2 assembly aids (assembly pins), instead of 2 wheel bolts, into the wheel hub before wheel 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, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

46 Checking the thickness of the disc brake pads Turbo and GT2

299

46 Technical data/Brake wear limit Turbo with PCCB

Technical data Turbo with ceramic brake discs (PCCB) Wear limit technical data Turbo with ceramic brake discs (PCCB) top of page

Technical data Turbo with ceramic brake discs (PCCB)

Designation Operating brake (foot brake) with ceramic brake discs (special request)

Notes, dimensions

Wear limit

Brake booster (vacuum) Boost ratio Brake master cylinder

Hydraulic dualcircuit brake system with frontaxle / rearaxle brakecircuit distribution. Vacuum brake booster, internally ventilated and perforated ceramic brake discs with sixpiston monobloc fixed caliper on the front axle and fourpiston on the rear axle. The brake calipers are painted yellow for visual differentiation. PSM* 1) (Porsche Stability Management) standard. 10 inch 3,85 25.4 mm 25.4 mm 18/18 mm EBV ** 2) 350 mm (PCCB) 350 mm (PCCB) 284 mm 291 mm 2 x 38 mm 2 x 32 mm 2 x 28 mm 2 x 30 + 2 x 28 mm 448 cm2 248 cm2 696 cm2

front rear Stroke front rear front rear front 6piston rear 4piston front rear

Brake proportioning control ** Brake discs Effective brake discs Piston in brake caliper

Brake pad area Total brake pad area

1) *

Porsche Stability Management (PSM) standard with ABS, Traction Control (TC), ABD, MSR (engine drag torque control), FZR (vehicle regulator) and EBV (electronic brake distributor). Passive switching 46 Technical data/Brake wear limit Turbo with PCCB 300

einordnung possibility for TC, FZR and MSR. 2) ** EBV = electronic brake distributor (brake proportioning control). As a result, no screwin brake proportioning valves are required! top of page

Wear limit technical data Turbo with ceramic brake discs (PCCB)

Designation Pad thickness Brake disc thickness, new Brake discs minimum thickness Thickness tolerance of the brake discs, max. Lateral runout of the brake disc, max. Lateral runout of the wheel hub, max. Lateral runout of the brake disc when installed, max. Pushrod play (measured at the brake pedal plate) Parking brake (handbrake) Parking brake drum Brake shoe width Brake pad thickness

front rear front rear front rear

Note, dimensions approx. 12.0 mm approx. 12.0 mm 34 mm 28 mm

Wear limit 2 mm 2 mm

33.5 mm 27.5 mm 0.02 mm 0.03 mm 0.03 mm 0.06 mm approx. 1 mm Drum brake acting mechanically on both rear wheels 180 mm 181 mm 25 mm 4.5 mm 2 mm

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Technical data Turbo with ceramic brake discs (PCCB)

301

47 Tightening torques for brake hydraulics

Location Brake pressure line to brake master cylinder, brake hose, distributor, brake caliper and hydraulic unit Hydraulic unit on holder Hydraulic unit to body Booster pump for PSM Booster pump on holder Booster pump on body at front Brake caliper Connecting line to brake caliper Bleeder screw to brake caliper Brake pressure line to brake caliper Brake unit Brake unit on body Brake unit support on body Brake master cylinder on brake booster Thread Tightening torque Nm (ftlb.)

M10 x 1 M12 x 1 M8 M6 M6 M6 M10 x 1 M10 x 1 M10 x 1

1214 (910) 20 (15) 12 (9) 10 (7.5) 7 (5) 4 (3) 12 (9) 8 12 (6 9) 12 14 (9 10) 23 (17) 23 (17) 49 (36)

M8 M8 M14

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

47 Tightening torques for brake hydraulics

302

48 Tightening torques for steering

Location Steering gear to cross member* Tie rod (ball joint) to steering arm Universal joint (steering shaft) to steering gear** Tie rod to ball joint (lock nut) Tie rod to steering rack Steering wheel to steering shaft Airbag module to steering wheel Steering outer tube to pedal bearing block, top Steering outer tube to pedal bearing block, bottom Steering lock to steering outer tube Transverse support to steering outer tube Transverse support to support frame Pressure and return pipes to steering gear Plugin couplings for steering hydraulic system Thread Tightening torque [Nm] (ftlb.) M10/10.9 65 (48.8)* 1) M12 x 1.5/10 75 (56.3) M8 23 (17.3)** 2) M14 x 1.5 50 (37.5) M16 x 1.5 80 (60) M16 x 1.5 45 (33.8) M6 10 (7.5) M10 x 1.5 46 (34.5) M14 20 (15) M6 13 (9.8) M8 23 (17.3) M8 23 (17.3) M10 x 1.5 20 (15) *** 3) a/f 15 30 (22.5) *** 3) a/f 19 40 (30)

1) *

Replace screws whenever removed. Replace fit bolt whenever it has been removed. 3) *** a/f = width across flats or wrench size (a/f 15 pressure line / a/f 19 return line).
2) **

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

48 Tightening torques for steering

303

48 Test and assembly work on power steering

General Checking hydraulic fluid of power steering and servo clutch Bleeding the steering system top of page

General
Damage to the power steering is caused by a shortage of oil in the hydraulic system. Even small leaks can cause the fluid to escape and damage the servo pump as a result of the high oil pressure occurring in the hydraulic circuit. Gruntlike noises when the steering is locked or foam formation in the reservoir indicates a shortage of oil and/or that air has also been sucked 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.

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 filled into the reservoir. Pentosin CHF 11 S can be ordered with the following part number: Quantity supplied 1 litre = 000.043.203.33. Note There is a second tank in the luggage compartment for clutch operation. This container is located under a cover! Rackandpinion steering gear and servo pump must not be repaired or dismantled!

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Checking hydraulic fluid of power steering and servo clutch

Note Power steering and clutch operation are supported by hydraulic auxiliary forces! The reservoir is located in the engine compartment! The dipstick located on the reservoir cap has the "Cold marking" (approx. 20 C engine temperature) 48 Test and assembly work on power steering 304

einordnung on one side and the "Hot max" symbol on the other side.

Pentosin reservoir Check the fluid level (Pentosin CHF 11 S) with the engine stationary and cold (approx. 20 C). CAUTION Danger of damage to property if too much Pentosin CHF 11 S is filled or if it comes in contact with the coolant hoses when topping up or filling in! Observe the following 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 reservoir! Fluid 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 IMMEDIATELY! Replace visibly swollen coolant hoses! 1. Start engine and run it at idle speed for approx. 20 seconds. Switch off engine. 2. Open the engine cover. 3. Open reservoir cap. 4. Wipe off the dipstick. Close and then reopen the cap. The fluid level should 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 warmedup condition, the fluid level must not exceed the "Hot max" mark! top of page

Bleeding the steering system

1. To fill the whole system after the installation of new steering components or lines or after a substantial loss of hydraulic fluid, briefly start the engine a few times and, when it fires, switch it off again immediately. This procedure causes the fluid level in the reservoir to fall rapidly, so constantly add Pentosin CHF 11 S. The reservoir must not be sucked dry. 2. If the fluid level in the reservoir does not fall any further when the engine is briefly turned over, start the engine and let it run at idling speed. 3. Rapidly turn the steering wheel from stop to stop several times so that the air can escape from the cylinders. At the end positions of the piston, do not pull the steering wheel with more force than is necessary in order to turn the steering (to prevent unnecessary buildup of pressure initially). 4. Observe fluid level during this procedure. If it continues to fall, add fluid until the level in the reservoir remains constant and no more air bubbles rise in the reservoir when the steering wheel is Checking hydraulic fluid of power steering and servo clutch 305

einordnung turned. 5. Switch off engine. 6. Wipe off the dipstick. Close and then reopen the cap. The fluid level should 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 warmedup condition, the fluid level must not exceed the "Hot max" mark!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Bleeding the steering system

306

48 Assessment of steering gear after accident damage

Fundamentals top of page

Fundamentals
Various kinds of damage can be caused to the steering gear in the event of accidents or driving conditions resembling accidents. In cases where the steering gear shows no external damage it can be difficult and costly to detect damage. Nevertheless, this damage represents an unacceptable risk for the vehicle, since it could lead to failure of the steering system. Since a comprehensive check on all individual parts of the steering gear is not feasible, as a rule, and is not possible using the ordinary means of a workshop, instead the condition of other components that are easier to check should be considered. The following guidelines serve for a decision on whether the steering gear of a vehicle involved in an accident should be replaced or may continue to be used.

Assessment of the steering of a vehicle involved in an accident

The steering gear can remain in the vehicle if all the following conditions are met: No visible damage to such frontaxle parts as wheel rims, spring struts, wheel carriers, control arms, steering arms, track rods, frontaxle cross member, frontaxle side members, the steering shaft or to the points on the body where wheel suspension parts are bolted on. No impermissible rise in torque and no jamming or catching when the steering gear is turned from stop to stop. When the steering is turned, the front wheels must be free (front axle raised) and, in addition, the engine must be switched off (pump of power steering undriven). The permissible tolerances for wheel alignment must not be exceeded. The steering gear must be repaired or replaced if one of the following points applies: Visible or detectable damage to the steering gear. Fire damage (e.g. steering bellows burnt). Permanent deformation or breakage of: Steeringgear mounts Track rods Steering arms Spring struts Wheel carriers Control arms Frontaxle side members Frontaxle cross member If the listed criteria are insufficient for a decision, we recommend that the steering gear be repaired or 48 Assessment of steering gear after accident damage 307

einordnung replaced.

Exceptional regulation / order handling

If a workshop's intended exchange of steering gear is refused by a customer or insurer for reasons of costs, an expert or if this is impossible abroad, the importer should be called in 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 powersteering gears that have to be exchanged are available as an exchange part.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Assessment of the steering of a vehicle involved in an accident

308

69 Safety regulations for vehicles with airbag and belt tensioner

Note Assembly and adjustment work Handling airbag and belt tensioner General information Note As from model year 2002, the front threepoint belt will be fitted with a belt tensioner as standard. WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! (Part 1) Please observe the following points: The airbag units are pyrotechnical items in hazard class T 1! Handling, transport and storage of these units must conform to the explosives legislation! The listed statutory requirements refer to the Federal Republic of Germany! The relevant valid regulations must be observed in all other countries! The commencement of work with pyrotechnical items must be reported 14 days in advance to the Trade Supervisory Office (responsible authority)! Airbag units may only be dispatched in transport packaging officially approved for that purpose! Airbag units may not be transported with other hazardous goods! Internally, they must always be transported in the luggage compartment or cargo hold of a vehicle using the abovementioned transport packaging! They must not be transported 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 objects may be stored at certain locations without special storage approval! According to the Explosives Storage Directive of August 1997, these quantities are max. 10 kg (net) in a work room and max. 100 kg (net) in a storage room in the case of Class T 1 pyrotechnical items! WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! (Part 2) Please observe the following points: Airbag units must be kept in a locked place! When storing airbag units, ensure that the airbag opening faces upwards (risk of injury caused by inflation of the airbag units in the event of accidental ignition)! Airbag units must be stored in a dry place and must not be stored together with other hazardous goods (varnishes, etc.)! Loose airbag units, referred to as airbag modules below, or airbag modules installed in a loose steering wheel must never become the actual (physical) property of the customer! The possession of loose airbag modules not installed in the vehicle is not permissible in the private sector! Airbag modules may become the property of the customer only when installed in the vehicle! 69 Safety regulations for vehicles with airbag and belt tensioner 309

einordnung

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Assembly and adjustment work

DANGER Danger of injury through malfunction of airbag system. Never drive with an unlocked triggering unit airbag. As long as the airbag triggering unit is not locked, the warning light lights up continuously. The triggering unit is locked with the Porsche System Tester. WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! Please observe the following point: Inspection and assembly work may only be carried out by specialist staff Before working on the airbag system and also when working on neighbouring parts where there is a risk because live parts are close to the airbag system, always implement the following safety measures: 1. Remove ignition key. 2. Disconnect and cover the negative terminal of the battery. WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! (Part 1) Please observe the following points: Inspection and assembly work may only be carried out by specialist staff! After the battery is disconnected, assembly work or work on the vehicle with a hammer or similar tools may not be started until after a waiting period of 1 minute! This is necessary 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 ensure it is not triggered accidentally! Airbag units must be fitted immediately after being removed from their storage location! On no account may airbag units be left lying around unsupervised! If work is interrupted, airbag units must immediately be locked away again! Airbag units must not come into contact with grease, oil, cleaning agents or similar substances! Airbag units may not be exposed to temperatures above 90 C! Airbag units and control units which have fallen from a low height may no longer be installed! No additional linings, stickers or similar may be attached to the steering wheel in the vicinity of the passenger's airbag and side airbag! No changes may be made to the wiring and to the components of the airbag system! The battery must always be disconnected before starting straightening and welding work with an electrical welding unit! Electrostatic charge: in general, suitable work clothing and footwear are to be worn. => Materials Never connect airbag units to electrical power sources not in accordance with regulations (danger of immediate ignition). Only use testers prescribed by the manufacturer. 0, 6901 Airbag diagnosis .

Assembly and adjustment work

310

einordnung WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! (Part 2) Please observe the following points: The control module must be removed in advance if you have to perform welding in the immediate vicinity of the control module! Airbag components may not be repaired! Airbag components must always be replaced! Wash your hands after touching triggered airbag units!

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Handling airbag and belt tensioner

Dangers for persons and the environment

Note Injury caused by incorrect triggering of the installed unit. Injury caused by 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 explosive dust, especially in older models. Irritation due to skin and eye contact with slag produced by the explosion, especially in older models. Airbag/belt tensioner components should neither be opened or repaired; always use only new parts. Injury caused by incorrect triggering due to manipulation of the short circuit bridge.

Protective measures and rules of behaviour

Note Assembly work only by trained staff. Carry out tests only with the Porsche System Tester diagnostic module; do not use test lamps, voltmeters or ohmmeters.

Handling airbag and belt tensioner

311

einordnung Do not bring into contact with grease, solvents or cleaning agents. Do not expose to temperatures above 100C. Keep the unfolding area of the airbag clear; e.g. do not hang test devices over the steering wheel. When carrying, hold the airbag with the blowout direction facing away from the body. Store the unit with the airbag facing upwards. Electrostatic charge: in general, suitable work clothing and footwear are to be worn. => Materials Do not remove the shortcircuit spring of the plug contacts. Never connect airbag units to electrical power sources not in accordance with regulations (danger of immediate ignition). Only use testers prescribed by the manufacturer. 0, 6901 Airbag diagnosis . During installation/removal or work on the vehicle involving shocks: switch off ignition, disconnect and cover the negative terminal of the battery, wait 1 minute and only then 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 installation of the airbag/belt tensioner unit must be carried out immediately after removal from the transport container. If work is interrupted, the airbag/belt tensioner unit must be stored in the transport container again. Leaving the belt tensioner unit unsupervised is not permitted.

Behaviour in cases of malfunction or danger

Note Protect against flames and heat. In case of fire, inform the fire brigade on arrival about the units present. Do not install mechanically damaged units or units that have fallen from a low height. Always replace units that are mechanically damaged (bulges, cracks). Because of the irritating combustion residues, only handle triggered airbags with protective gloves and goggles. In the case of contact with combustion residues, wash the affected skin with soap and water.

Protective measures and rules of behaviour

312

einordnung In the case of eye contact, wash the eyes with water.

Materials

Item

Special tool designation Porsche work clothing

Remarks Gr. 2.6; Workshop Equipment Manual

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General information
The airbag system is constantly monitored by a diagnosis unit in the triggering unit. Any fault is signalled by a warning light. The warning light for the airbag system lights up in the event of a fault. The airbag warning light lights for approx. 3 seconds after the ignition is switched on and goes out if no fault has been entered in the fault memory. If it lights up again, this indicates a fault in the system. The fault can be read out with the Porsche System Tester 2. Note A period of 10 seconds is required to enable the triggering unit to identify all faults in the system! In order to guarantee that every possible fault source is checked during the vehicle test, the ignition must be switched on 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 Maintenance booklet! To do this, attach the documentation number in a free panel intended for that purpose! The documentation number is attached to the replacement part as a tearoff sticker! Exchanged airbag units or airbag modules must be taken into possession by the Porsche Centre or by a dealer authorised by Porsche and must not be handed over to the customer (customer has no right to possess them). They must be destroyed, disposed of or returned to the manufacturer in accordance with the explosives ordinance and the hazardous materials ordinance! When the steering wheel is exchanged, e.g. to install a steering wheel from the Tequipment product range, the airbag unit of the replaced steering wheel must be removed and destroyed, disposed of or returned to the manufacturer before the steering wheel is handed over to the customer!

Behaviour in cases of malfunction or danger

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Component exchange after airbag triggering

The following components must be removed and replaced after the airbag system is triggered: After triggering of the airbag unit on the driver's side: Contact unit Airbag unit, driver's side After triggering of the airbag unit on the passenger's side: Airbag unit, passenger's side Triggering unit after the third time the airbag is triggered

After triggering of the side airbag unit

Side airbag unit Sensor for the side airbag unit after the third time the side 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 side airbag). All belt tensioner units Note Because it is difficult to visually determine if one or both belt tensioners has been triggered, check the following points. Read out the airbag fault memory with the Porsche System Tester. Check plug connection on the belt tensioner for damage. Pull out the belt strap as far as possible and check for wear. Perform a function test on the automatic belt device.

996420, 996421, 996450, 996451, 996840, 996841

Component exchange after airbag triggering

314

87 Nominal values for pressures and temperatures

Note General test prerequisites Note The temperature of the air from the centre dashboard vents must lie within the prescribed tolerance range within 5 minutes, depending on the ambient temperature!

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General test prerequisites

Close doors, windows and sliding roof. Insert temperature probe into centre vent. Measure ambient temperature. Open all dashboard vents. Switch ignition on. Press circulation button. Set temperature control to maximum cooling. Switch freshair blower to stage 4. Start engine. Operate air condition while idling. Set engine speed to 2000 rpm (start of time measurement). Note If the prescribed nominal values are not reached, the cooling system must be checked for leaks and repaired!

Centre vent temperature as a function of ambient temperature

87 Nominal values for pressures and temperatures

315

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High pressure in cold circuit as a function of ambient temperature

Low pressure in cold circuit as a function of ambient temperature

Centre vent temperature as a function of ambient temperature

316

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996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Low pressure in cold circuit as a function of ambient temperature

317

91 Retrofitting mobile communication systems

Note Note Observe the installation specifications and recommendations listed in the operating instructions! When mobile phones and twoway radios are correctly installed, they are not influenced by important vehicle systems such as e.g. ABS, airbag and Motronic! The installation and wiring of vehicle systems must not be altered! A wiring arrangement parallel to these systems and their wiring harnesses (especially sensor wires) is not permitted! In general, it is necessary to get approval for the installation of mobile communication systems (car telephone, mobile phone, twoway radios, etc.) in a vehicle that received its type approval after 1st January, 1996. Mobile twoway radios (telephones) that are retrofitted must have a type approval for this vehicle and be identified with an 'e'. In the Driver's Manual of its vehicles, Porsche has approved mobile telephones and twoway radios with a maximum transmission power of 10 W. Porsche permits the installation and operation of twoway radios over 10 W for the radio services listed below under the following preconditions: The transmission powers in the given frequency range may not exceed the respective Pmax values at the antenna base. The installation must be carried out correctly and a nonreflecting adapted external antenna must be used. Always observe the operating and installation instructions of the manufacturer for mobile phones, twoway radios and antennas.

Volume Short wave up to 54 MHz 4m band 2m band 70 cm 23 cm Cnet Dnet Enet

Pmax /Watt 50 (PEP) 20 (eff.) 50 (eff.) 50 (eff.) 20 (eff.) 25 (eff.) 20 (PEP) 10 (PEP)

Permitted location of antenna on vehicle outside on vehicle outside on vehicle outside on vehicle outside on vehicle outside on vehicle outside on vehicle outside on vehicle outside

Note If a mobile phone or twoway radio is retrofitted which does not conform to Porsche installation conditions, the general certification of the vehicle can be rendered null and void (EU EMV Vehicle regulation 95/54)!

91 Retrofitting mobile communication systems

318

einordnung In this case it is necessary to have EMV experts inspect the Porsche in order to observe the protective goals! The optimum range of the twoway radios can only be reached with an external antenna! Excessive electromagnetic fields can occur in the vehicle from the operation of mobile phones and twoway radios without an external 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, a suitably chosen antenna location and a reduction of transmission power if necessary ensure adherence to the limit values of the DIN VDE 0848 Part 2 (Protection of persons in a frequency range of 30 kHz to 300 Ghz)!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

91 Retrofitting mobile communication systems

319

96 Additional alarm system M 536

Note Removing alarm siren and tilt sensor Note Vehicles for Great Britain and Belgium are equipped with an alarm siren and tilt sensor in addition to the standard alarm system! M 590 (lid release locks) is also standard equipment in these vehicles!

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Removing alarm siren and tilt sensor

1. Remove cover for fluid reservoir (air conditioning). 2. Pull off connector on the alarm siren. 3. Pull off connector on the tilt sensor.

4. Undo nut.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

96 Additional alarm system M 536

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97 Measurement of closedcircuit current

Tools Preparations on the vehicle Measurement top of page

Tools

Closedcircuit current should be measured using an analog ammeter or a digital multimeter with a long integration time (to filter out voltage peaks). Item 1 Special tool designation Multimeter 155 Remarks Gr. 2.5; Workshop Equipment Manual

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Preparations on the vehicle

Note Before measuring the closedcircuit current, determine the vehicle equipment (Mnumbers) and establish the expected closedcircuit 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 luggagecompartment lid with a suitable tool e.g. upper part of the lock with a suitable grip with the luggagecompartment lid open. 3. Remove the ignition key and lock the vehicle with the key (alarm system is activated).

Connecting measuring device

1. Set the measuring device to the highest possible current measuring device. 2. With two alligator clips, connect the measuring instrument to the battery ground and to the second body 97 Measurement of closedcircuit current 321

einordnung ground which is always available for RHD or LHD versions. 3. Remove ground strap from the body and secure against contact with the body. The onboard current now flows via the ammeter. top of page

Measurement
Select a measuring range which ensures that the pointer of the instrument is in the upper third of the scale, as far as possible. Switch over measuring range without interruption. Read off the measured values only after the waiting period specified in the table. Do not switch on any electrical consumers during the measurement (open central locking system, etc.). Note If the value of the closedcircuit current is higher than the value determined in the table, the cause must be established. The recommended procedure for troubleshooting: With the measuring 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 troubleshooting, screw the ground strap back on to the body in the proper manner. The measured values may deviate by approx. 20%. The values listed in the table depend on the condition of the battery, the ambient temperature and the engine temperature. Reading off the measuring range: Read off the measuring range only when at least 61 minutes have passed since the vehicle was locked. From 0 min. 6 min. 16 min. 21 min. 61 min. To 5 min. 15 min. 20 min. 60 min. Until battery empty mA Up to approx. 950 Up to approx. 900 Up to approx. 750 Up to approx. 50 Up to approx. 30

Control module Generator DME Instrument cluster Immobilizer/central locking Connecting measuring device

Equipment Standard Standard Standard Standard

Closedcircuit current in mA 0.5 0.3 1.4 13 322

einordnung Passenger compartment monitoring/tilt sensor Power windows, front Tiptronic* ABS PSM Radio CD changer Amplifiers, audio Navigation information system Navigation computer PCM2 as from MY '03 Telephone as from MY '03 Both seat memeories Climatronic Standard production vehicle Additional equipment Maximum equipment M No. 534 Standard M No. 249 Standard 6.6 1.1 0.4 0.1 0.1 1.0 0.8 0.3 1.2 0.7 2.8 0.2 1.6 0.03 Approx. 19 Approx. 12 Approx. 31

M No. 692 M No. 490 M No. 662

M No. 537 M No. 573 Total Total Total

Note * After prior disconnection of the battery, terminal 15 must have been connected to the control module at least once.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Measurement

323

27 06 Battery
Note Battery handling notes Removing and installing battery Remove battery Install battery Visual inspection Check acid level Checking gravity of electrolyte Opencircuit voltage measurement Battery load test Charging battery Note To prevent contact corrosion, only approved screws, nuts, discs etc. should be used. These elements have a special surface coating and must be stored separately. The battery is one of the most important electrical components in the vehicle. Faultfree functioning of the battery contributes greatly to customer satisfaction. To guarantee long and efficient operation, the battery must be checked and maintained 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 page

Battery handling notes

Note Battery terminals should not be greased. The battery terminal clamps should only be attached without force to prevent damage to the battery housing. The tightening torque for the battery clamps is 5 Nm (4 ftlb.). If the battery is to be reconnected, proceed according to 9 work instructions after disconnecting the battery . To guarantee that the battery does not leak, it is necessary that the original plug accompanying the battery is screwed into the battery openings. In the case of loss or damage, only original plugs of the same design should be used. The plugs must be fitted with an oring seal.

27 06 Battery

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Warning notes and safety regulations for hydrocyanic acid batteries

1. 1 Fire, sparks, naked flames and smoking are forbidden: Avoid sparking when using cables and electrical devices Avoid short circuits.

In batteries with central venting, there is an increased detonating gas concentration. The vent hose should not be bent or blocked by dirt. 2. 2 Wear eye protection 3. 3 Keep children away from acids and batteries. 4. 4 Danger of causticization: Battery acid is highly caustic, therefore wear protective gloves. Do not tip battery, acid can emerge from the venting 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 soap suds and rinse again with plenty of water. If acid has been drunk unintentionally, consult a doctor immediately. 5. 5 Observe information on the battery, in the Technical Manual and in the Driver's Manual. 6. 6 Danger of explosion: A highly explosive detonating gas mixture occurs when charging batteries. 7. 7 Disposal: Hand in old batteries at a collection point. 8. 8 Never dispose of old batteries in the domestic rubbish! top of page

Removing and installing battery

Note

Warning notes and safety regulations for hydrocyanic acid batteries

325

einordnung The battery is located in the radiator tank. In order to avoid triggering the alarm siren (installed on right next to the battery) of vehicles with M 536, the battery must be disconnected with the ignition on! All loads must be switched off beforehand! Remove ignition key! Never disconnect battery with engine running! Never start engine without securely connected battery! The battery terminal clamps should only be attached without force to prevent damage to the battery housing. Battery terminals should not be greased. Check that the battery is seated correctly after installation. Other dangers exist with a loose battery such as: Reduced service life due to vibration damage. Damage to the grid 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 the latest state of the art are fitted with central venting. The gas occuring during the charging, emerges centrally through an opening on the upper cover side. The backfire protection is integrated into the same position which prevents the ignition of the combustible gas present in the battery. In batteries with hose/pipe for the central venting, ensure that the hose is not disconnected. Only then can the battery be freely vented. In batteries without a hose/pipe for the central venting, ensure that the opening is not blocked on the upper cover side of the battery.

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Remove battery
1. Switch ignition off and remove ignition key.

Removing and installing battery

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einordnung

2. Open turnlock fasteners A . 3. Remove battery cover. 4. First disconnect the ground strap of the battery on the negative battery terminal. Unscrew hexagon nut and remove terminal.

5. Undo hexagon 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 battery
Note => Removing and installing battery 1. Insert battery.

2. Screw in fastening screw B , position battery and tighten the fastening screw. Tightening torque:

Remove battery

327

einordnung 23 Nm (17 ftlb.) 3. Push on vent hose A . 4. First connect the positive cable then the negative otherwise there is a danger of a shortcircuit! Tightening torque: 5 Nm (3.5 ftlb.). 5. Put on the battery cover and lock with the turnlock fasteners. 6. 9 Carry out work instructions after disconnecting the battery. top of page

Visual inspection
Before measurements such as opencircuit voltage, gravity of electrolyte or the battery load test are carried out, a visual inspection of the battery must be performed. Through this check, it can be determined: Whether the housing of the battery is damaged. Acid can leak out due to damage of the housing. Whether the battery terminal (battery line connections) is damaged. Contact of the line connections cannot be guaranteed if the battery terminal is damaged. This can cause a line fire and malfunctions in the electrical system.

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Check acid level

CAUTION The accident prevention regulations must be observed 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 naked flame. Do not handle a naked flame or lit cigarettes near batteries. Observe the disposal regulations for batteries when disposing of batteries and sulphuric acids. Note Use a commercially available battery filling bottle. The correct acid level of the battery is an important factor for long and efficient operation of the battery. When the acid level is too low, a capacity loss (performance loss) of the battery occurs which is caused by the cell plates drying out. If the cell plates are not surrounded by electrolyte (battery acid), it will lead to corrosion of the lead plates, the plate bridges and the cell connectors. The result of the corrosion is that battery functioning cannot be guaranteed. The battery will become useless. If the acid level is too high, damage can occur by the battery acid leaking out (sulphuric acid water mixture) outside the battery. 1. Switch ignition off and remove ignition key. Install battery 328

einordnung

2. Remove battery cover. 3. Unscrew battery plugs. 4. Shine a torch into the battery. The electolyte level of the battery must be at the protruding lug . If the acid level is too low, refill distilled water using the battery filling bottle. 5. Screw in plug of the battery again and ensure that it is seated correctly. 6. Remount battery cover. top of page

Checking gravity of electrolyte

CAUTION The accident prevention regulations must be observed when handling battery acids. Wear suitable protective clothing. Observe the disposal regulations for batteries when disposing of batteries and sulphuric acids. Note Use 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 The temperature of the battery acid must be at least 10C . The gravity of electrolyte must be checked in all battery cells as follows. 1. Switch ignition off and remove ignition key. 2. Unscrew all battery plugs (plugs of the battery cell). 3. Dip the acid siphon or the pipette into the battery cell and take up the battery acid. 4. Read off the gravity of electrolyte in kg/dm on the scale of the battery acid tester and compare with the following table. Battery charging condition in Spec. normal climatic zones gravity in kg/dm discharged 1.12 half charged 1.20 well charged 1.28

Check acid level

329

einordnung Battery charging condition in tropical climatic zone (hot countries) discharged half charged well charged Spec. gravity in kg/dm 1.08 1.16 1.23

The gravity of electrolyte must be at least 1.24 kg/dm. If the gravity of electrolyte is too low, charge battery. After charging the battery, repeat the electrolyte gravity test. The measuring values for the gravity of electrolyte of the individual battery cells should not deviate by more than 0.03 kg/dm from eachother. Examples of nonpermissible specific gravity of electrolyte deviations: Battery cell: 1 2 3 4 5 Gravity of electrolyte per cell in kg/dm Example 1: 1.24 1.25 1.25 1.10 1.24 Example 2: 1.26 1.26 1.25 1.14 1.18

6 1.25 1.24

Example 1: The gravity of electrolyte 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 nominal values are not achieved, replace battery. If the nominal values are achieved, screw in the original plug again. top of page

Opencircuit voltage measurement

Note Use a handheld multimeter to measure the battery voltage. Gr. 2.5; Workshop Equipment Manual 1. Switch ignition off and remove ignition key. 2. Disconnect ground strap on the battery. Note After charging and a waiting time of at least 2 hours during which the battery should neither be loaded or charged. 3. Measure the battery voltage with a handheld multimeter. The battery opencircuit voltage should not fall below 12.5V. If the handheld multimeter shows 12.5V or over, the battery voltage is OK. Checking gravity of electrolyte 330

einordnung If the handheld multimeter shows a battery voltage below 12.5V: Charge battery. top of page

Battery load test

Note The electrolyte gravity test provides information about the state of the battery in connection with the battery load test. A battery test device is required for the load test. Gr. 3.9.1; Battery test charge device, Workshop Equipment Manual. The battery must not be removed or disconnected. The battery must be charged before the load test is performed. Carry out battery load test: 1. Switch ignition off and remove ignition key. 2. Observe the information in the operating instructions of the battery test device. 3. Connect the pliers of the test lines to the battery terminal as described in the operating instructions of the test device. As the load current varies, the current must be set depending 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 instructions and compare to the test result of the following tables. A minimum voltage is determined by the battery load test depending on the specified battery voltage. Table: Battery capacity: Cooling test current Load current Minimum voltage (limit value) 5. If the minimum voltage is not attained, replace battery. Remarks on battery load test: The battery voltage sinks during this test due to the severe load on the battery. If the battery is in order, the voltage value only reduces to the minimum voltage. If the battery is faulty, the battery voltage will sink very quickly below the specified minimum voltage. After the test has taken place, the low voltage value remains over a long period of time, the voltage increases again slowly.

80Ah 380A 300A 9.5V

Opencircuit voltage measurement

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Charging battery
WARNING The battery plugs must always be screwed in correctly when charging and during the voltage measurement and the load measurement. Rooms in which batteries are being charged, should not be entered with a naked flame or when smoking. Gases form through the charging process in the batteries which are highly flammable. Note A battery charging device is required. Gr. 3.9.1; Battery test charge device, Workshop Equipment Manual. Observe charging device operating instructions. The battery must have a minimum temperature of 10C. Do not charge batteries too quickly if possible as they can be damaged in this way. If totally discharged batteries are charged quickly, they will not take up a charge current or they will be indicated too early as being full by the socalled surface charge . 1. Switch off battery charging device. 2. Switch ignition off and remove ignition key. 3. First disconnect the ground strap of the battery, then the positive battery terminal. 4. Connect positive 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 the battery of the charge device according to the battery capacity. 7. Switch on battery charging device. Procedure for loading totally discharged batteries: Batteries which are not in operation for a long period of time, discharge. A battery is totally discharged if the opencircuit voltage has sunk below 11.6V. => Opencircuit voltage measurement In totally discharged batteries, the battery acid (sulphuric acid water mixture) consists of virtually only water, as the sulphuric acid proportion is considerably reduced. Totally discharged batteries sulphatise, i.e. the entire plate surface of the batteries harden. If totally discharged batteries are immediately recharged after an exhaustive discharge, the sulphatisation recedes again. If these batteries are not recharged, the plates continue to harden and charge takeup ability is limited. A reduction in the battery performance is the result. Totally discharged batteries must be charged with a low charge current as follows:

Battery load test

332

einordnung Set charge current 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

Charging battery

333

27 06 Electrical emergency release, front cover

Note Emergency release, front cover Note In the event of a flat battery, the release engines of both covers can be supplied with electricity, via a battery jump lead. A red marked emergency power unit is located on the fuse box in the driver's footwell. This emergency power contact can be pulled approx. 3 cm out of the fuse box, on which the plus side of the auxiliary lead is connected. The transferring of the electricity supply to the release motors is carried out by a changeover relay (mini relay), located on the rearside of the fuse box. Should the door be locked (alarm protected), an alarm would sound if somebody attempted to connect the auxiliary lead. Turn off alarm system by locking and then unlocking the door.

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Emergency release, front cover

1. Unlock the vehicle at the door with the key. 2. Remove cover on the fuse box and pull emergency power contact out of the fuse box.

3. Connect red auxiliary wire (positive) onto this contact.

27 06 Electrical emergency release, front cover

334

einordnung

4. Connect second auxiliary wire (negative) onto the vehicle ground (e.g. onto the lock bar of the Bpillar). 5. Connect auxiliary wire to an appropriate 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. 8. Clip cover back onto the fuse box.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Emergency release, front cover

335

40 09 Frontaxle cross member permissible combinations

New frontaxle cross member as of model '02 Allocating the frontaxle cross member to the body top of page

New frontaxle cross member as of model '02

As of model '02, the frontaxle cross member is attached to the body at the rear fastening with two screws arrows . Up to this point (up to the end of model '01), only one screw was used for fastening. The tightening torque has not been changed. The previous frontaxle cross member F1 , with one fastening screw securing it to the body (per side) is still available as a spare part. Only certain combinations of frontaxle cross member attachment F1 or F2 to the body are permitted! F2 2 fastening points (as of model '02) F1 1 fastening point top of page

Allocating the frontaxle cross member to the body

CAUTION Material damage will result in the area of the axle mount/axle fastening due to reduced strength, if correct allocation is not observed! Only install permissible combinations of frontaxle cross member to the body (standard construction)! Do not install frontaxle cross members with one fastening screw (F1) in vehicles with two body mounting points (K2)!

40 09 Frontaxle cross member permissible combinations

336

einordnung

Impermissible combination

Frontaxle cross member with one fastening bore F1 and body with two fastening points K2 . Attention: Impermissible combination!

Permissible combinations

Frontaxle cross member with one fastening bore F1 and body with one fastening point K1 . Standard construction up to end model '01.

Frontaxle cross member with two fastening bores F2 and body with two fastening points K2 . Standard construction as of model '02.

Impermissible combination

337

einordnung

Impermissible combination
The combination frontaxle 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

Impermissible combination

338

40 Disassembling and assembling front spring strut

Tools Disassembly and assembly instructions top of page

Tools

Item Designation of the special tool Spring clamp

Explanation Commercially available in accordance with Technical Equipment Manual, Chapter 2.4, No. 12. Clamping range of spring holder up to 165 mm spring diameter on one side and 195 mm spring diameter on the other side.

40 Disassembling and assembling front spring strut

339

einordnung

No. 1

Designation Fastening nut M 14 x 1

Qty. 1

2 3

Stop plate

Spring strut mount 1

Removal Installation Before loosening the fastening nut, Use new fastening nut. Tighten tension coil spring with the spring to 80 Nm (59 ftlb.). clamp. Counter at the piston rod when loosening the nut. Mount in correct position (No. 2 and No. 7 are identical parts). The "RI" or "LE" code for the right or left side respectively is stamped on the top of the spring strut. Remove the mount from backup Make sure it is seated properly ring No. 4 only when replacing the in the backup ring No 4. mount (Lever out mount with a small screwdriver). 340

4 4A

Backup ring Mount

1 1

Tools

einordnung 5 Spring plate (compensation part) Coil spring Stop plate 1 Observe allocation as per Spare Parts Catalogue. Observe allocation as per Spare Parts Catalogue. Mount in correct position (No. 7 and No. 2 are identical parts). Mount in correct position. Mount on protective bellows (No. 10) Tighten to 10 Nm (7.5 ftlb.). The screw must be fitted in the direction of travel. Right and left side are different (the cast number 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.

6 7 8 9 10 11 12 13

1 1

Cup washer 1 Additional spring 1 Protective bellows 1 Nut 1 Screw 1 Spring seat 1 Loosen spring seat from the vibration damper only when replacing it.

14 15

Washer

The washer is inserted in the spring seat. Observe allocation as per Spare Parts Catalogue.

Vibration damper 1

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Disassembly and assembly instructions

Disassembly
CAUTION Danger of injury due to spring tensioning! Never use an impact bolter to loosen or tighten the fastening nut! Use commercially available changeover ratchet! Note When installing new parts, observe the allocation according to the Spare Parts Catalogue! To undo the connection piston rod to spring strut mount counter at the piston rod with countering tool 9630 or a 7mm Allen key. Disassembly and assembly instructions 341

einordnung 1. Tension the coil spring with the spring clamp until the piston rod is relieved. 2. Remove all parts from the piston rod. Note Disassemble backup ring 4 and mount 4A only in the case of replacement.

3. Lever out the mount with a small screwdriver.

Distinguishing feature of coil springs and dampers

A Identification of the running gear version (spring constant/spring length) by two different coloured 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 (spring plate) thickness. 1 white line = 3.0 mm thick compensation part 1 green line = 6.5 mm thick compensation part C Colour dot (colour label) to differentiate the damper identifier.

Preliminary work and notes on assembly

Note Observe the correct allocation (running gear version) when installing new springs and/or dampers! It is recommended to replace the coil springs only in pairs! Disassembly 342

einordnung If the coil springs are exchanged, it might be necessary to use a different spring plate than before! 1. Replace nut for fastening the piston rod on the spring strut mount. The following spring plates (compensation parts) are available: 1 white line = 3.0 mm thick compensation part

1 green line = 6.5 mm thick compensation part

2. Complete mount 4A , backup ring 4 and spring plate 5 (compensation part). 3. Fit protective bellows on additional spring. 4. Tension coil spring with spring clamp.

Assembly
CAUTION Danger of injury due to spring 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, align the appropriate spring seat in the centre before tightening. The spring seat fastening screw must be installed in the direction of travel when doing this. Note Space constraints and the position of the stabilizer mount are decisive factors. The stabilizer mount must be free of tension at complete right and left stops (ball heads still movable)! After the spring strut is installed, the position of the spring seat must be checked again and may need minor adjustment!

Preliminary work and notes on assembly

343

einordnung Spring seats for the right and left sides are different! The distinguishing feature of the spring seat is a cast lug on the left spring seat! Also, a different cast number is stamped on the bottom of the spring seat! Example: 996 343 508 02 even number for right side. 996 343 507 02 odd number for left side. 1. Slide the protective tube/additional spring assembly onto the piston rod. 2. Slide the cup washer 8 and stop plate 7 as far as they will go into the correct position on the piston rod.

Vibration damper 3. Place pretensioned coil spring on the vibration damper. 4. Place the mount/backup ring/spring plate assembly on the coil spring.

Note

The "RI" or "LE" code and a positioning arrow for installation in the correct position in the vehicle are stamped on the top of the spring strut mount arrow ! 5. Place the left or right spring strut mount on the left or right section accordingly. 6. Place stop plate in the correct position on the spring strut mount and screw a new fastening nut onto the piston rod.

Assembly

344

einordnung

Note

Use a socket wrench insert open on one side to tighten the fastening 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, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Assembly

345

42 71 Disassembling and assembling rear spring strut Turbo

Tools Disassembling and assembling rear spring strut Disassembly and assembly instructions top of page

Tools

Item Designation of the tool Spring clamp (e.g. from Klann) with spring holder

Remarks Commercially available, clamping range of spring holder up to 165 mm spring diameter

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Disassembling and assembling rear spring strut

42 71 Disassembling and assembling rear spring strut Turbo

346

einordnung

No. Designation 1 Fastening nut M 12 x 1.5

2 3

Stop plate Spring strut mount

Qty. Removal 1 Before loosening the fastening nut, tension coil spring with the spring clamp. Support at the piston rod with an openended wrench (7 mm) when loosening the nut. 1 1 Remove complete assembly (mount with intermediate part No. 9 and spring plate No. 10).

Installation Use new fastening nut. Tighten to 58 Nm (43 ftlb.). First position springstrut mount 3.

Intermediate part 1 (compensation

Mount in correct position. No. 2 and No. 6 are identical parts. The mounts for the right and left sides are identical parts. Position the mount before tightening the fastening nut No. 1. Observe allocation. Join in correct position with spring 347

Disassembling and assembling rear spring strut

einordnung part) Spring plate Stop plate plate No. 5. 1 1 1 1 1 1 1 Observe allocation as per Spare Parts Catalogue. Observe allocation as per Spare Parts Catalogue. The vibration dampers for the right and left sides are identical parts. Fit in correct position (groove facing snap ring). Ensure perfect seating. Mount in correct position (No. 2 and No. 6 are identical parts). Mount on protective bellows (No. 9)

5 6 7 8

Washer Additional spring 9 Protective bellows 10 Coil spring 11 Vibration damper

12 Spring plate, bottom 13 Snap ring

1 1

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Disassembly and assembly instructions

Disassembly
CAUTION Danger of injury due to spring tensioning! Never use an impact bolter to loosen or tighten the fastening nut! Use commercially available changeover ratchet! Note Observe the correct allocation (running gear version) when installing new springs and/or dampers! It is recommended to replace the coil springs only in pairs! If the coil springs are exchanged, it might be necessary to use a different spring plate than before!

Disassembly and assembly instructions

348

einordnung

1. Tension the coil spring 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 a 7mm openended wrench. 3. Remove all parts from the piston rod. 4. Replace nut for fastening the piston rod on the spring strut mount. Preliminary work and notes on assembly: 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 white line = 0.5 mm thick compensation part (natural colour)

5. Press intermediate part (compensation part 4 ) into the spring plate 5 in the correct position (not twisted) and complete with the mount 3 . Observe following note! Note In the correct position means: None of the 7 cutouts A must be free on the spring plate 5 !

Disassembly

349

einordnung 6. Fit protective bellows on additional spring.

Distinguishing feature of coil springs and dampers

A Identification of the running gear version (spring constant/spring length) by two different coloured lines (for example, 1 x gold and 1 x red). Refer to the Parts Catalogue for the allocation. B Identification of the coil spring tolerance group (load group) for determination of the compensation part (spring plate) thickness. Coil spring with: 1 green line = 4.0 mm thick compensation part (black) 1 white line = 0.5 mm thick compensation 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 = RoW running gear Red colour dot = USA running gear 1. Tension coil spring with spring clamp. 2. Clamp eye of vibration damper in the vice (use jaw liners).

Assembly
CAUTION Danger of injury due to spring tensioning! Never use an impact bolter to loosen or tighten the fastening nut! Use commercially available changeover ratchet! 1. Place pretensioned coil spring on the vibration damper. 2. Slide the protective tube/additional spring assembly onto the piston rod.

Distinguishing feature of coil springs and dampers

350

einordnung

3. Slide the washer 7 and stop plate 6 (No. 6 in correct position) as far as they will go onto the piston rod.

4. Place the spring strut mount (assembly of spring strut mount / intermediate part / 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 fastening nut onto the piston rod until approx. 1 to 2 threads are visible above the fastening nut. Note The mounts for the right and left sides are identical parts!

Assembly

351

einordnung

The mount is positioned correctly if one of the 3 fastening pins is aligned with the holder on the damper tube! 7. Position the spring strut mount for installation (correctly position spring strut mount with respect to the damper). 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 fastening nut! 9. When tightening the fastening nut, hold at the piston rod using a special tool 9630 countering tool or a 7 mm openended wrench.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Assembly

352

44 27 Instructions for collapsible wheel/spare wheel Turbo with PCCB

Mounting collapsible spare wheel Turbo with PCCB Placing collapsible spare wheel in to the vehicle Turbo with PCCB top of page

Mounting collapsible spare wheel Turbo with PCCB

Note

The collapsible wheel is mounted at the front or rear axle wheels using the standard wheel bolts A M14 x 1.5 (length 45 mm) dimension X ! WARNING Vehicles with PCCB (Porsche Ceramic Composite Brake): 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 heavy contact of the wheel with the brake disc.

Screw the two enclosed assembly pins, instead of two wheel bolts, into the wheel hub before wheel removal/mounting. During removal, first remove the three 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 Nos.: 999 571 074 30.

44 27 Instructions for collapsible wheel/spare wheel Turbo with PCCB

353

einordnung top of page

Placing collapsible spare wheel in to the vehicle Turbo with PCCB

1. After using the collapsible spare wheel, release the air by unscrewing the valve case. Note It takes several hours for the tyre to resume its original form! It can only be stowed in the spare wheel recess in the luggage compartment after it has resumed its initial form! 2. After releasing the air, fasten the tension straps lying opposite. To this purpose, pull the straps through the rim and place around the tyre. Position the straps 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 so that the tension straps lie to the front and to the rear. Note The collapsible spare wheel may only be repaired by the manufacturer. In the case of vehicles with PCCB, the spare wheel cannot be stowed in the spare wheel recess without securing it with the tension straps! The loops on the tension straps simplify the removal of the collapsible spare wheel or its placement in the vehicle.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Mounting collapsible spare wheel Turbo with PCCB

354

45 60 Steering angle sensor

Calibrating steering angle sensor top of page

Calibrating steering angle sensor

WARNING Malfunctions in the PSM control range if the steering angle sensor is not calibrated or is calibrated incorrectly! Calibrate the steering angle sensor with the wheels in straightahead position! Note A steering angle sensor is attached to the steering column/steering shaft for the PSM (Porsche Stability Management)! PSM is standard 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)!

Steering angle sensor position

The steering angle sensor has no defined zero position when new. The position for "straight ahead" direction of travel must be programmed. This is done by calibrating with the Porsche System Tester 2 with the wheels in straightahead position.

The steering angle sensor must be calibrated after:

1. A new steering angle sensor has been installed, 2. The PSM control device has been exchanged, 3. 45 60 Steering angle sensor 355

einordnung The steering gear and / or components which change the zero position of the steering angle sensor have been exchanged, 4. Accident repairs, 5. Suspension alignment procedures during which the previous wheel alignment values were changed.

Calibrating steering angle sensor

WARNING Malfunctions in the PSM control range if the steering angle sensor is not calibrated or is calibrated incorrectly! Calibrate the steering angle sensor with the wheels in straightahead position! Note Check the steering angle sensor actual value with wheels in straightahead position before calibrating the steering angle sensor! Only recalibrate the steering angle sensor on the measuring platform if the steering angle actual value lies outside the tolerance or is doubtful! 1. Drive vehicle onto measuring platform. Affix measuredvalue pickups to all wheels. 2. Check wheel alignment values and adjust if necessary. If the wheel alignment values on the front and rear axles are correct, calibrate the steering angle sensor with the front wheels in straightahead position. Calibration description in following text. 3. Select the "Calibrate steering angle sensor" menu with the Porsche System Tester 2 in the PSM system. Entry to the PSM system takes place through the ABS system (automatic status change after PSM). 4. Confirm calibration start. The procedure can also be interrupted. 5. Vehicle wheels in straightahead position. Note This safety code must be extracted in the Actual Values menu, Safety Code submenu! The safety code changes automatically each time provided that PSM is called up again! The calibration procedure will be interrupted if an incorrect safety code is entered! This timeconsuming procedure ensures that the steering angle sensor is not calibrated unintentionally! The steering angle sensor can be calibrated several times! The value (the zero position) is stored in the steering angle sensor itself! 6. The PST 2 now requests the 4digit safety code shown in the display. 7. Input the 4digit safety code with the cursor keys (4 centre keys on right). Then continue with the (>>) key. Note The steering angle sensor must be calibrated after: 356

einordnung The final possibility to interrupt the calibration is not to confirm the safety code input! To do this, press the appropriate function key for no! 8. Confirm safety code input. Display in the Tester display after the safety code input has been confirmed: Steeringangle sensor being calibrated. For safety reasons, read out the current steering angle sensor actual value after calibration. To do this: 9. Leave the PSM system. Then call up PSM again and select the steering angle sensor in the Actual values menu. Required display in the Tester display: 0 3 when the wheels are in straightahead position. 10. Repeat the calibration if the value 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 sensor calibration.

Checking the steering angle sensor actual value

1. Connect the Porsche System Tester 2 to the diagnostic socket. 2. Select vehicle type and then enter PSM system. Entry takes place through the ABS system (automatic status change after PSM). 3. Select steering angle sensor in the Actual values menu. 4. Required display in the Tester display with wheels in straightahead position 0 3 . 5. If the steering angle sensor actual value deviates or is doubtful, recalibrate the steering angle sensor on the measuring platform.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Calibrating steering angle sensor

357

66 72 Assignment of spoiler drive, relays and instrument cluster

Note Variants of the spoiler drive Note In the case of the 911 Turbo (996), it is essential when replacing the spoiler drive, the relay no. 9 or the instrument cluster to note that only the variants listed in the table below can be installed together. Relay no. 9 is located on relay carrier 2. Variant 1 concerns the series launch vehicles up to production date 02.05.2000. This variant can no longer be installed. If the drive module is defective, a variant 2 module must be installed. Variant 2 concerns the vehicles as from production date 02.05.2000 up to the model change 2002. Instrument clusters with the 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 model '02.

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Variants of the spoiler drive

Version Current no. of Rear spoiler the rear spoiler drive module drive module 1 00253 to 00750 996.512.241.00 (not spare part) 2 From 00751 to 996.512.241.01 model '02

Relay No. 9, extend spoiler 996.615.102.00 996.615.122.00

Instrument cluster

As from '02 model

996.512.241.01

996.615.102.00

996.641.213.00 FFF to 996.641.218.00 FFF 996.641.213.00 FFF to 996.641.218.00 FFF 996.641.213.01 FFF to 996.641.218.01 FFF 996.641.213.02 FFF to 996.641.218.02 FFF (instrument cluster with integrated shutdown delay for rear spoiler)

996420, 996421, 996450, 996451 66 72 Assignment of spoiler drive, relays and instrument cluster 358

69 59 Disposal of airbag and belt tensioner units

Note Safety measures when igniting airbag units Tools Connecting ignition tool Ignition Note Countryspecific statutory regulations and legislation based on them which go beyond these instructions must always be observed and take precedence over these instructions! As from model year 2002, the front threepoint belt will be fitted with a belt tensioner as standard. WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! Please observe the following points: Before disposal, the airbag units must be rendered harmless by electrical ignition and while observing all precautionary measures, thereby preventing them being used incorrectly! Note Airbag units are pyrotechnical items and can pose an environmental hazard! For this reason, nonignited airbag units or entire vehicles must not be disposed of as normal scrap, refuse or in other final storage facilities. If the vehicle had suffered fire damage which caused one or several airbags or the belt tensioner to be ignited, additional ignition with the ignition device 9257 must be carried out in order to ensure that only parts without pyrotechnical contents are scrapped! In the case of airbag units which cannot be ignited or if the conditions for safe ignition are insufficient, always return the airbag units to Porsche or the respective importer in their original packaging!

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Safety measures when igniting airbag units

WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! Please observe the following points:

69 59 Disposal of airbag and belt tensioner units

359

einordnung Ignition and preparations may only be carried out by skilled staff, supervised by a second responsible person! Other normal accident prevention regulations must also be observed! Ignite airbag units only in their securely installed, original condition! Carry out ignition only in suitable, free areas! Use only the ignition tool intended for that purpose! All loose objects must first be removed from the expansion area of the airbag! Persons possibly affected must be informed of the resulting noise beforehand! 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 front of the vehicle. This also applies to persons not involved! Perform ignition with the doors closed and the side windows open! Do not approach the vehicle until after a waiting period (approx. 3 minutes) if ignition fails! Allow airbag units to cool down under observation following ignition! Avoid skin contact with ignited airbag units!

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Tools

Ignition cable for belt tensioner

Item A

Designation Ignition device

Special tool 9257*

Remarks

Safety measures when igniting airbag units

360

einordnung B C D E Ignition cable Ignition cable Ignition cable Ignition cable 9567 9566 9257/2 9257/3 For driver's airbag For passenger's airbag For side airbag For belt tensioner

* Order if required top of page

Connecting ignition tool

Driver's side

Connect the ignition device 9257 with the adapter cable 9567 directly to the 2pin plug of the driver's airbag contact unit (under the steering column).

Passenger's side

Connect the ignition device 9257 with the adapter cable 9566 to the passenger's airbag plug connection. Place the ignition device in front of the vehicle through the door gap.

Side airbag

Tools

361

einordnung

Connect the ignition device 9257 with the adapter cable 9257/2 to the side airbag plug connection. 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 in front of the vehicle through the door gap. top of page

Ignition

Side airbag

362

einordnung Note The driver's and passenger'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, 996841

Ignition

363

87 03 Safety regulations when handling refrigerant R134a

The refrigerant R 134a which is used is known as a safety refrigerant. This means that this refrigerant is nonflammable, nonexplosive, nontoxic, nonirritating, odorless and tasteless. Despite this, you should still follow the points below: WARNING Danger of injury as a result of contact with liquid or gaseous refrigerants! Wear rubber gloves to protect your hands! Treat affected skin in the same way as in the case of freezing. Rinse immediately with cold water and then consult a physician! Wear safety goggles to protect your eyes! If refrigerant still gets in your eyes, consult a physician immediately! CAUTION Danger of fire due to the airconditioning system heating up from sunlight shining into the vehicle or during welding and soldering work! When carrying out repairs on the airconditioning system, the system must be emptied by suction and the refrigerant must be purified. Chlorinefree refrigerants must also not be allowed to escape into the 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 or hotair heating may take place on parts of the filled airconditioning system or in its immediate vicinity! Make sure that parts of the airconditioning system do not heat up during welding or soldering work on the vehicle! While drying after painting work, the temperature burden on the vehicle must not exceed two hours at a maximum temperature of 80C! Whether or not the system is filled with refrigerant, the heating causes a very strong overpressure which can cause damage to the system or even lead to an explosion! R 134a is completely nontoxic at normal temperatures, but it decomposes upon contact with a flame or at high temperatures! Refrigerant bottles must not be thrown and must not be subjected to direct sunlight or other heat sources for an extended period when full! The maximum permissible temperature of a filled refrigerant bottle must not exceed 45 C!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

87 03 Safety regulations when handling refrigerant R134a

364

92 66 Nonadjustable spray nozzles

Note Note The new spray nozzles for the windscreen washer system 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 (nonadjustable)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

92 66 Nonadjustable spray nozzles

365

94 23 Bulb table and installation instructions

Bulb table Installing bulbs top of page

Bulb table

Lamp High beam headlight, dipped beam headlight Auxiliary high beam headlight Fog light Direction indicator light Rear fog light Reversing light Brake light/parking light Tail light Parking light, front Side direction indicator light Additional brake light Number plate light

Shape, Output D2S, 35 W H 11, 55 W H 3, 55 W PY, 21 W P, 21 W P, 21 W P, 21 W P, 5 W H, 6 W W, 5 W W, 3 W C, 5 W

top of page

Installing bulbs
CAUTION Danger of damage to property if bulbs are used or handled incorrectly! Only bulbs specified 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 bulbs must be clean and free of grease. Therefore, never touch bulbs with your bare hands!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 23 Bulb table and installation instructions

366

96 22 Bulb table and installation instructions

Bulb table Installing bulbs top of page

Bulb table

Interior light, door warning light Luggage compartment light Bulbs

Shape, Output W5W K 10 W 1.5 W

top of page

Installing bulbs
Note Only bulbs specified 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 bulbs must be clean and free of grease! Never touch bulbs with your bare hands! Use a cloth or soft paper for changing bulbs!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

96 22 Bulb table and installation instructions

367

97 68 Optical waveguide MOST bus

Note Specifications on handling the optical waveguide Plug connectors Removing and installing optical contacts Optical waveguide modules Tools Note The optical waveguide will be used as from model year 2003.

top of page

Specifications on handling the optical waveguide

The plug connections must not be connected or disconnected with tools. The optical waveguide and the plug copnnections must not be brought into contact with liquids such as water, leakage fluids, preservers, antifreeze fluids or cleaning agents. This may impair the function of the MOST system or even complete system failures. Even plug connectors with connected protective caps must not be brought into contact with the listed liquids. If the optical contacts, plug connectors or bushings are not connected or the connectors are not equipped with protective 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 must not be stored in the open air. The optical waveguides must be protected from direct sunlight when stored. The optical waveguides must not be exposed to high levels of air humidity when stored. Recommended storage conditions: Temperature between 20C and +40C, air humidity between 40% and 60%. The optical waveguides must be stored in cardboard boxes or plastic bags. No forces may be exerted on the stored optical waveguides which could deform or damage them. The optical waveguides may only be stored with connected dust protective caps. During storage, the bending radius of 30 mm must always be maintained. Optical waveguides with damaged surfaces must be replaced.

Installing optical waveguides in the vehicle

The limit values listed below must not be exceeded when installing an optical waveguide in the vehicle:

97 68 Optical waveguide MOST bus

368

einordnung Maximum permissible tensile load: 60 N Minimum bending radius after and during installation in vehicle: 25 mm Maximum number of torsions: 10 torsions per m The following points must be observed when installing optical waveguides and wiring harnesses containing optical waveguides: Damaged optical waveguides must not be installed. Before installing the optical waveguide or the wiring harness with optical waveguide into the vehicle, you must check whether the protective dust caps have been attached properly. If this is not the case, the optical waveguide set must not be installed. After and during installation of the optical waveguide into the vehicle, the minimum bending radius of 25 mm must be maintained. During installation of the optical waveguide into the vehicle, the optical guide must not be pulled to set the length of the wiring harness (max. tensile load 60 N) and the optical guide must not be twisted or coiled up. After installation of the optical waveguide 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
Defective optical guides must be replaced. Repairs for optical waveguides are not planned. When replacing optical waveguides, the optical contacts must be removed form the plug connectors. top of page

Plug connectors

Protective dust caps

Protective dust cap for optical contacts: If an optical waveguide is stored, transported or installed in a vehicle, the protective dust cap most only be removed immediately before use in the plug. The protective dust cap must be replaced after every test of an optical waveguide. The protective dust caps can be removed without actuating a lock. During or after removal of the protective dust cap, do not touch the exposed contact surfaces, because otherwise the optical contacts may be damaged or soiled. Protective dust cap for plug (wiring harness side): If a readymade wiring harness is installed, protective dust caps are already present on the plug for the optical waveguide.

Installing optical waveguides in the vehicle

369

einordnung

By actuating the lock arrow , the protective dust cap can be pulled off. The protective dust cap must be replaced after every test of an optical waveguide. During or after removal of the protective dust cap, do not touch the exposed contact surfaces, because otherwise the optical contacts may be damaged or soiled.

Control module plug connector (wiring harness side)

The optical waveguide is delivered with plastic 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 wiring harness >> control module (optical input). Black contacts are used for the transfer control module >> wiring harness.

Connectors
Structure of an optical waveguide connector:

1 Optical contact, black 2 Optical contact, grey 3 Connector, plug side 4 Connector, bushing side 5 Bushing side optical waveguide module 6 Optical contact, grey 7 Optical contact, black 8 Springs 9 Spring cap

Protective dust caps

370

einordnung top of page

Removing and installing optical contacts

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 front luggage compartment:

Connectors

371

einordnung

Disconnecting plug connector at CD changer: Remove CD changer.

Disconnecting plug connector of control module for telephone: Remove passenger's seat 7, 720119 Removing and installing 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 pressout tool. Insert the tool in the appropriate opening and raise the lock. The lock then engages in the upper setting => Tools.

Removing and installing optical contacts

372

einordnung

2. Position tool at the primary lock and raise the lock. A Optical contact, grey B Optical contact, black 3. Pull carefully on the optical waveguide, e.g. B in the direction of the arrow . If it is not possible to pull out the optical waveguide, check again whether the secondary lock has been completely unlocked and whether 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 optical contacts on plug side

Remove the protective dust cap immediately before the connection procedure. Check that the contact is in proper condition.

1. Push optical contact B into the plug until it engages audibly. A Optical contact, grey B Optical contact, black

Removing optical contacts on plug side

373

einordnung 2. Close the secondary lock arrow and check for proper seating of the optical contacts.

Removing optical contacts on bushing side

1. Unlock and remove the spring cap on both sides using the pressout tool => Tools. 2. Remove the optical waveguide module from the plug.

3. Position the unlocking tool at the contact lock of the optical waveguide module and raise the lock. A Optical contact, grey B Optical contact, black 4. Pull carefully on the optical waveguide, e.g. B in the direction of the arrow . If it is not possible to pull out the optical 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 damaged parts.

Installing optical contacts on bushing side

Remove the protective dust cap immediately before the connection procedure. Check that the contact is in proper condition. Given a force of 10 N, the springs installed at the connector are pressed together. This leads to an increase in the absorption, which may lead to system impairments or even system failures. Therefore it is only permissible to pull the optical waveguide out of the connectors with a maximum force of 10 N.

Installing optical contacts on plug side

374

einordnung

1. Push the optical contacts B and A into the module until they engage perceptibly. Check for proper seating of the optical contacts.

2. Connect the module to the connector on the bushing side. 3. Push the spring cap on to the connector until it engages perceptibly arrow . top of page

Optical waveguide modules

At least one transmitter 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 created, in which the light signal in every control module is refreshed (the light signal is converted to an electrical signal in every control module). The graphic below shows the wiring of the individual MOST control modules which varies according to the particular equipment.

Installing optical contacts on bushing side

375

einordnung 1 MOST control modules: A Radio/PCM, lead 1 in connection with amplifier or CD changer without telephone. A Radio/PCM, lead 2 in connection with telephone without amplifier and CD changer. A Radio/PCM, lead 3 in connection with telephone and amplifier or CD changer. B Amplifier, 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 connector, located above the brake booster. top of page

Tools

Pressout tool:

Item 1

Special tool designation Pressout tool 155/ 88069

Remarks Gr. 2.4; Workshop Equipment Manual

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Optical waveguide modules

376

01 Sales check
Working position 01 01 00 00 Working instruction to order no. Workshop no. Vehicle Ident. No.

OK Not 1) OK 2) Check conformity of vehicle Ident. No. on vehicle, data bank, vehicle registration documents and onboard literature => Checking the Vehicle Ident. No. Remove transport locks, transport protection => Removing transport lock (spring strut locking devices) &ndash; Turbo and GT2 Battery: check battery charge state (take transport and idle period into account) => Battery&colon; checking the charge state Diagnostic system: read out or erase fault memory, activate systems => Diagnostic system&colon; Read out fault memory and activate systems Windscreen washer/headlight cleaning system: check operation, fluid level and nozzle settings, pay attention to antifreeze protection in the winter months => Windscreen wiper&sol;washer system, headlight washer Vehicle lights: check operation. All headlights: check adjustment. Horn and clock: check operation => Checking the function of the vehicle's lights and the headlight setting Electrical 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; checking function Check engine oil level Check tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure Wheels, tyres: visual inspection for damage => Tyres and spare wheel&colon; checking condition and tyre pressure Check wheel mounting => Checking the wheel mounting Brake hoses and lines: visual inspection for damage in the wheel area => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discsCheck brake fluid level => Checking and changing the brake fluid Visual inspection for leaks: oils, fluids Exterior equipment and paint finish, visual inspection for damage => Checking the exterior equipment and paint finish Glazing: visual inspection for damage => Glazing&colon; visual inspection for damage Interior equipment: visual inspection for damage and soiling => Interior equipment&colon; visual inspection for damage and soiling Door and lid locks: check operation => Checking lid and doors Alarm system: checking operation of indicators => Alarm system&colon; checking operation of indicators 01 Sales check 377

einordnung Complete vehicle and check equipment for completeness => Completing vehicle and checking equipment for completeness => Fitting front lip &ndash; GT2

Test drive Foot and parking brakes, clutch, steering, automatic speed control, ParkAssist, heating, airconditioning 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 erase fault memory => Diagnostic system&colon; Read out fault memory and activate systems
1) OK 2) Not

OK Not 1) OK 2)

= functioning correctly OK = not functioning correctly

Stamp of Official Porsche Centre

996430, 996431, 996420, 996421, 996450, 996451, 996840, 996841

01 Sales check

378

03 24 00 Minor maintenance
Note Note Not valid for USA. The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module). On vehicles with annual mileages of less than 15,000 km (9,000 mls), an annual maintenance must be carried out once a year. Maintenance with oil filter change must be carried out at least every 2 years according to the mileage, if the mileage for a major maintenance has not already been reached. For an annual mileage of more than 15,000 km (9,000 mls) we recommend carrying 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 reconditioning parts or assemblies.

Minor maintenance after: OK 20,000, 60,000, 100,000, 140,000 km etc./ 12,000, 36,000, 60,000, 84,000 mls etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out 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: visual inspection for completeness, installation and damage Power steering: check fluid level => Steering gear&colon; fluid level and bellows Coolant hoses: check condition Radiators and air inlets at front: visual inspection for external contamination and blockage Coolant: check the level and antifreeze protection => Checking cooling system Particle filter: replace filter element => Particle filter&colon; replacing the filter element Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid Drive shafts: visual inspection of the boots for leaks and damage => Axle joints&sol;drive shafts Tyres and spare wheel (collapsible wheel): check condition and tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and functioning properly => Checking lid and doors

03 24 00 Minor maintenance

379

einordnung Vehicle lighting: check function; 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 antifreeze protection in the winter months => Windscreen wiper&sol;washer 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 lights Test drive: Remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996840, 996841

03 24 00 Minor maintenance

380

03 26 00 Major maintenance
Note Note Not valid for USA! The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module). 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 assemblies. The maintenance item > Throttle actuation: Check smooth operation, check full throttle position with the Tester < omitted as of model year 2002.

Major maintenance after OK 40,000, 80,000, 120,000, 160,000 km etc./ 24,000, 48,000, 72,000, 96,000 mls, etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out fault memory 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 and engine compartment: visual inspection for leaks (oils and fluids) and abrasion (lines and hoses) Underbody 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: check the level and antifreeze protection => Checking cooling system Air cleaner: replace filter element => Replacing air cleaner element Particle filter: replace filter element => Particle filter&colon; replacing the filter element Fuel system: visual inspection for damage, routing and secure fit of line connections Power steering: check fluid level => Steering gear&colon; fluid level and bellows Parking brake: checking the free play of the parking brake lever => Parking brake&colon; checking the free play of the parking brake lever Brake system: visual inspection of the brake pads and brake discs for wear => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid Clutch: play or pedal end position is to be checked => Clutch&colon; checking the play and pedal end position Throttle actuation: check smooth operation, check the full throttle position with the Tester 03 26 00 Major maintenance 381

einordnung Steering gear: visually inspect the bellows for damage => Steering gear&colon; fluid level and bellows Checking the tie rod end play and dust bellows => Axle joints&sol;drive shafts Axle joints: check play, visual inspection of dust bellows for damage => Axle joints&sol;drive shafts, check screw connections of running gear adjustment facility, front and rear, for secure fit => Running gear adjustment&sol;storage of assemblies Drive shafts: visual inspection of the boots 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 => 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 secure 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 => Checking the function of the vehicle's lights Windscreen 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 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, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996840, 996841

03 26 00 Major maintenance

382

03 50 00 Annual maintenance
Note Note Not valid for USA. The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module). On vehicles with annual mileages of less than 15,000 km (9,000 mls), an annual maintenance must be carried out once a year. Maintenance with oil filter change must be carried out at least every 2 years according to the mileage, if the mileage for a major maintenance has not already been reached. For an annual mileage of more than 15,000 km (9,000 mls) we recommend carrying 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 reconditioning parts or assemblies.

Annual maintenance OK Diagnostic system: read out fault memory => Diagnostic system&colon; reading out fault memory Vehicle underside 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 inlets at front: visual inspection for external contamination and blockage => Checking cooling system Power steering: check fluid level => Steering gear&colon; fluid level and bellows Engine: check oil level => Changing the engine oil and oil filter Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid Steering gear: visually inspect the bellows for damage => Steering gear&colon; fluid level and bellows Tie rod ends: checking the play and dust bellows => Axle joints&sol;drive shafts Axle joints: check the play and visually inspect the dust bellows for damage => Axle joints&sol;drive shafts Drive shafts: visual inspection of the boots for leaks and damage => Axle joints&sol;drive shafts Tyres and spare wheel (collapsible wheel): check condition and tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure

03 50 00 Annual maintenance

383

einordnung Vehicle lighting: check function; all headlights: check adjustment; horn: check operation => Checking the function of the vehicle's lights 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 lights Test drive: Remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 50 00 Annual maintenance

384

10 01 00 Tightening torques for M 96/70 engine

Crankshaft/crankcase Cylinder, cylinder head and camshaft housing top of page

Crankshaft/crankcase
Note The fastening screw of the belt pulley must always be replaced.

Location Initial tightening of connectingrod screws Final tightening of connectingrod screws Oil pump on crankcase half Crankcase bolts (through bolts) Hexagon nuts or hexagonhead bolts on crankcase Belt pulley on crankshaft Flywheel on crankshaft Drive plate on crankshaft (Tiptronic) Drive plate on converter (Tiptronic) Plugs of pressure relief valve on crankcase Oil drain plug on crankcase Screwed socket in crankcase Plug on crankcase half at upper right (former oil pressure sensor mounting location) Driver of exhaust turbocharger oil extraction pump on intermediate shaft

Thread M9 x 1.25 M9 x 1.25 M8 M10 x 1.25 M8 M14 x 1.5 M10 M10 x 1.25 M8 M18 x 1.5 M20 x 1.5 M22 x 1.5 M18 x 1.5

Tightening torque Nm (ftlb.) 30 Nm [22 ftlb.] 10 % 90 2 25 (19) 50 (37) 23 (17) 170 (126) 85 (63) 90 (67) 39 (29) 50 (37) 70 (52) 70 (52) 30 (22) 25 (19)

top of page

Cylinder, cylinder head and camshaft housing

Note The axial camshaft adjuster central screws (inlet camshaft) and sprocket wheel (exhaust camshaft) must always be replaced.

10 01 00 Tightening torques for M 96/70 engine

385

einordnung

Thread Tightening torque Nm (ftlb.) M10 30 Nm (22 ftlb.), then unscrew; 20 Nm (15 ftlb.) (joining torque); then retighten all screws to 20 Nm (15 ftlb.); final tightening with 120 turn Camshaft housing (thread and sealing surface M8 (10.9) 23 Nm (17 ftlb.) initial tightening of screw head are lightly oiled) 28 Nm (21 ftlb.) final tightening Camshaft bearing cap on camshaft housing M6 (10.9) 13 (9.5) Oil guide housing (screws microencapsulated M5 (8.8) 7 (5) replace) Guide rail between the camshaft wheels M6 (10.9) 13 (9.5) Central screw for axial camshaft adjuster on the M12 x 30 Nm [22 ftlb.] initial tightening inlet camshaft; before tightening, the adjuster 1.5 x 120 170 torque angle (replace screw) must be positioned to the lefthand stop Sprocket wheel central screw on the exhaust M12 x 30 Nm [22 ftlb.] initial tightening camshaft (internal serration) 1.5 90 torque angle (replace screw) Guide/tensioning rail on crankcase 31 (23) Camshaft housing cover on camshaft housing, M6 (8.8) 10 (7.5) left /right Oil extraction pump on camshaft housing M6 10 (7.5) Control valve for axial camshaft adjuster M27 x 25 (19) 1.5 Holder for valve lift adjustment control valve M6 10 (7.5) Water pump bracket and engine carrier on M10 65 (48) crankcase (10.9) Screw plug for exhaust turbocharger extraction M6 4 (3) pumps Screwed socket for exhaust turbocharger return M16 x 30 (22) line 1.5 Oil drain plug on oil container exhaust M18 x 30 (22) turbocharger 1.5 Engine oil return line on neck/oil tank M30 x 60 (44) 1.5

Location Cylinder head nut (coat thread and sealing surface of the nuts with engine oil)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Cylinder, cylinder head and camshaft housing

386

10 10 37 Disassembling and assembling crankcase

Tools Adapting engine holder Left crankcase half (cylinder bank 1 3) Right crankcase half (cylinder bank 4 6) Disassembling the crankcase Assembling the crankcase. top of page

Tools

Item Designation A Engine holder

Special tool Holder P 201

Explanation Fasten to the right half of the crankcase (cyl. 4 6), only mount in connection with an adapter 9967 (order quantity, 2 ea.)

Toothed segment and Toothed segment and mounting elements mounting elements P 201 b

10 10 37 Disassembling and assembling crankcase

387

einordnung

Note If the special tool is to be screwed into position for the first time with the engine holder P 201, two threaded bores must be provided in addition.

Item

Designation Engine holder (adapter)

Special tool Engine holder 9667

Explanation Additional fastening of the crankcase via four studs.

Item A

Designation Holding wrench for belt pulley

Special tool Holding wrench 9548

Explanation

Tools

388

einordnung B C D Retaining device Retaining device 9662 For bracing the tension rod bolts when tightening

Surface seal Drei Bond Silicon Type 1209 Retainer plate Retainer plate P 209a

Screw the crankshaft to the retainer plate with internal serration screws Part No. 928.102.151 01. (order 3 pieces)

E F G H I J

Restraining straps (connecting rod) Nut with internal serrations, wrench size 14 for tension rod threaded part Assembly fixture for flywheel Snap ring pliers Special grease for connectingrod bearings Holder for cylinder

Restraining straps P 221

Retaining device P 238 b Commercially available Optimol Optipit 000.043.204.17 Set of retaining nuts For stabilising the retaining P 140 device 9662 when bracing the tension rod bolts

Item A B C E

Designation Insertion device for sealing ring Assembly sleeves for tension rod bolt seal Assembly aid Pressure piece for sealing ring

Special tool Pressin device P216 d Assembly sleeve 9511 Fastening plate 9517/1 Insert device 9517

Explanation

top of page Tools 389

einordnung

Adapting engine holder

Note The threaded bores must only be provided if the adapter ring is used for the first time.

No. 1 2 3 4 5

Procedure Centring adapter on engine holder Centring engine holder Reworking engine holder Fastening adapter on engine holder Engine holder with adapter half

Instructions

Adapting engine holder

390

einordnung 6 Mounting adapter half on crankcase

1. Centring adapter on engine holder. Fasten the adapter half with the already made bores arrows with two auxiliary screws M10 x 60 onto the engine holder. Spotdrill or countersink the engine holder slightly through the 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 drill with a drill bit 3mm, then with a drill bit 5mm.

3. Drill pilot hole and cut thread.

4. Fasten adapter on engine holder. Fasten adapter with the supplied cylinder screws onto engine holder with hexagon socket (M6 x 35).

Adapting engine holder

391

einordnung

5. Mount engine holder with adapter half. Screw engine holder with screwed in adapter half onto the crankcase half of the cylinder bank 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 tighten the assembly sleeves. top of page

Left crankcase half (cylinder bank 1

3)

Left crankcase half (cylinder bank 1

3)

392

einordnung

Note: No. Designation 1 Hexagonhead bolt M8 x 50 2 Holder 2a Fastening nut M8 3 Hexagonhead bolt M6 x 25 4 Hexagonhead bolt M6 x 35 5 Sensor holder 6 Plug 7 Sealing ring A22 x 27 8 Threaded insert M20 x 1.5 Qty. Removal Installation 1 1 1 1 1 1 1 1 3)

Tightening torque 70 Nm (52 ftlb.) Always replace

Left crankcase half (cylinder bank 1

393

einordnung 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Screwin flanges (oil return) Sealing ring A22 x 27 Screw plug for oil pressure relief valve M18 x 24 Sealing ring A18 x 24 Compression spring Piston for excess pressure valve Stud BM10 x 105 Stud Stud BM10 x 70 Stud M10 x 60 Dowel sleeve Hexagon nut M10 x 1.25 Washer A10.5 Fastening nut Washer Fastening nut Washer Multipletooth nut 1 1 1 1 1 1 2 24 1 1 1 1 1 1 1 18 18 11 Tightening torque 70 Nm (52 ftlb.) Always replace Tightening torque 50 Nm (37 ftlb.) Always replace Examine the piston and bore in the housing for traces of scoring, if necessary replace the piston, then oil Projection length 106 mm Projection length 150 mm Projection length 161 mm Projection length 169 mm Tightening torque 50 Nm (37 ftlb.) Replace Replace Replace Tightening torque 50 Nm (37 ftlb.), tighten with double hexagon wrench insert while bracing with retaining device, special tool 9662.

27 28 29 30 31 32 33 34

Washer Oring 8 x 2 Straight pin A8.0 x 2 Straight pin Oversize plug 8.5 x 8.0 Oversize plug 14.00 x 8.5 Oversize plug 20.0 x 13 Crankcase half of cylinder bank 1 3 35 Dowel sleeve 36 Oil spray jet for piston cooling

11 11 11 1 1 1 1 1 1 3

Apply surface seal to sealing surface

top of page

Right crankcase half (cylinder bank 4 6)

Right crankcase half (cylinder bank 4 6)

394

einordnung

No. 1 2 3 4 5 6 7 8 9 10 11

Designation Screw plug Piston Compression spring Guide sleeve Spacer ring Sealing ring A18 x 24 omitted omitted omitted Fastening nut M8 Washer 8.4

Qty. 1 1 1 1 1 1

Removal

Note: Installation Tightening torque 50 Nm (37 ftlb.) Oil

Replace

1 1 395

Right crankcase half (cylinder bank 4 6)

einordnung 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 Hexagonhead bolt M8 x 45 Fastening nut M8 Fastening nut Washer Hexagonhead bolt M8 x 55 Hexagonhead bolt M8 x 45 Crash support Tension rod bolts Washer Oring 8 x 2 Oring 8.3 x 2.4 Tension rod bolts Screw plug M18 x 1.5 Sealing ring A16 x 20 Screw plug M16 x 1.5 Sealing ring A16 x 20 Stud Stud BM10 x 110 Stud Stud BM8 x 22 Stud BM8 x 48 Stud BM10 x 105 Stud BM8 x 52 Stud BM8 x 28 Stud BM8 x 32 Stud BM10 x 140 Dowel sleeve Stud BM10 x 60 Panhead screw M10 x 18 Stud BM10 x 70 1 1 1 1 1 1 1 11 11 11 4 2 1 1 1 1 3 2 1 1 1 1 1 1 1 1 2 1 1 1

Replace Replace

Replace, oiled lightly Replace Tightening torque 30 Nm (22 ftlb.) Replace Replace Projection length 80 mm Projection length 110 mm Projection length 60 mm Projection length 22 mm Projection length 49 mm Projection length 107 mm

Projection length 69.5 Tightening torque 45 Nm (33 ftlb.). Projection length 60 mm

top of page

Disassembling the crankcase

Note The thrust plate, drive plate and the flywheel must be removed before fastening the engine onto the engine holder or assembly support.

Disassembling the crankcase

396

einordnung

1. Position the toothed segment special tool P201b on the stud and undo the panhead screws of the clutch pressure plate in several stages and in diametrically opposite sequence, to avoid deforming the thrust plate.

2. Fasten mounting device P238b with holder P140 onto the studs. Loosen flywheel screws and remove the 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 holder. See also subsection "Adapting engine holder". => Adapting engine holder Note The pulse sender should not be detached! Shear bolts were installed in the first vehicles.

Shear bolts on pulse sender 4. The shear bolts are replaced by microencapsulated hexagon head bolts

Disassembling the crankcase

397

einordnung M6 x 20.

Hexagon head bolts on pulse sender

5. Loosen belt pulley. To do this, a second person should counter with the holding wrench 9548 at the same time. Do not continue to use the hexagonhead 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 to the inside. Note The tension rod bolts in thrust blocks 2, 3, 4 and 5 arrows can only be removed after removing the crankcase half (cylinder bank 1 3). Disassembling the crankcase 398

einordnung

Removing tension rod bolts. 9. Crankcase half (cylinder bank 1 3).

10. Remove Orings and tension rod bolts of thrust blocks 2, 3, 4 and 5. top of page

Assembling the crankcase.

1. Fasten engine holder P201 to the right crankcase half (cylinder 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 intermediate shaft to the crankcase. The tolerance group number is imprinted on the crankcase arrow and must match the number on the intermediate shaft gearwheel and the crankshaft gearwheel.

Assembling the crankcase.

399

einordnung

Pairing number on crankcase

Pairing number on crankshaft gearwheel arrow

Pairing number on the intermediate shaft gearwheel 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 shaft. Insert new bearing shell halves in the crankcase half of the cylinder bank 4 6.

Assembling the crankcase.

400

einordnung

6. Oil the bearing surfaces. Insert intermediate shaft and check for true running. 7. Insert new crankshaft bearing shell halves into the crankcase. Oil the bearing surfaces.

8. Check that the dowel sleeves are present and seated properly. 9. Insert crankshaft (excluding mount 8) into the crankcase half of the cylinder bank 4 6. Note If the wear dimension has been 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 surface. The sealing surface must not be damaged during this procedure. Align the dial guage on a tooth profile and determine play. Subsequently turn the intermediate shaft by 180 and repeat the measurement. Circumferential backlash: New dimension 0.035 0.084 mm Wear dimension 0.10 mm 11. Remove intermediate shaft again. Assembling the crankcase. 401

einordnung 12. Let a second person lift the crankshaft slightly and push bearing no. 8 onto the crankshaft journal.

13. Lower the crankshaft slowly and insert crankshaft bearing no. 8 into the dowel 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 in the crankcase.

15. Grease sealing ring (19.5 x 26) on both sides and insert it into the crankcase half 4 6 in the area of the oil pump mount. Assembling the crankcase. 402

einordnung 16. Insert the complete unit, oil pump with dumbbell shaft and intermediate shaft with both timing chains into the crankcase half.

17. Fasten new collar nuts (3 pieces). Tightening torque 23 Nm (17 ftlb.).

18. Check dumbbell shaft. The dumbbell shaft must be easily movable in axial direction. If necessary, reloosen the oil pump with the intermediate shaft and shift the dumbbell shaft. Note Additional Orings are inserted on 4 tension rod bolts of the thrust block fastening, thrust blocks 2, 3, 4 and 5. The 4 tension rod bolts must be mounted before joining the crankcase halves.

19. Prepare the tension rod bolts for installation. The diagram shows the already mounted tension rod bolts in the designated thrust blocks. Note Do not oil sealing rings until shortly before fitting. Do not store oiled sealing rings.

Assembling the crankcase.

403

einordnung

Prepare four tension rod bolts. Push sealing washers on to tension rod bolts. Feed lightly oiled Orings with conical sleeve from special tool 9511 over the threaded area and push them on to the tapered section towards the head of the bolt.

Observe 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 sleeve on end of the thread. Push Oring (dry) over the conical sleeve. Remove conical sleeve and push the Oring with the cylinder sleeve as far as the chamfer in the thrust block. Remove cylinder sleeve.

Assembling the crankcase.

404

einordnung

Cylinder sleeve application

20. Lift connecting rod of cylinder 4, 5 and 6 with restraining straps, special tool P221. Lift timing chain with tension strap.

21. Coat both sides of sealing rings on the oil pump (2 pieces) and the sealing 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 the sealing surface of the crankcase halves. Apply a uniform bead of silicone (Drei Bond Typ 1209) approximately 1.5 mm wide to the sealing surface of the crankcase half of cylinder bank 1 3.

Assembling the crankcase.

405

einordnung

Check the relief groove in the area of the main bearing no. 7 for foreign objects, e.g. silicone residue and clean if necessary. Insert the crankcase half carefully over the preassembled tension 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. Join crankcase halves and secure with approx. 6 new fastening nuts with washers. Distribute the fastening nuts evenly on the periphery and tighten by hand.

Assembling the crankcase.

406

einordnung

25. Insert the prepared tension rod bolts of the crankcase half 4 6 and hold.

26. Push the conical sleeve of special tool 9511 with an oiled Oring to the end of the thread.

27. Push the Oring carefully away from the conical sleeve with the Aside (thin wall) of the cylinder sleeve.

View of the conical sleeve 28. Remove conical sleeve and carefully push round seal to its end position with the Bside (thick wall) of the cylinder sleeve, while bracing the bolt head. 29. Mount sealing washers (dry) and press downwards slightly with Bside of cylinder sleeve. 30. Screw on outer multipletooth nuts (thread oiled) by hand. 31. Proceed in the same way with both studs of the crankcase half 4 6 (area of bearing 1) on the flywheel side. Note Assembling the crankcase. 407

einordnung Cover the chain space briefly when fitting so that parts do not fall into the crankcase.

32. Mount hexagon nut M10 x 1.25 and washer A10.5 on stud, with rounded side pointing towards the hexagon nut. 33. Mount retaining device, special tool 9662, on corresponding tension 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 Oring is damaged when the tension rod bolts are turned. Use a 14 mm multipletooth socket from Snapon to counter.

Retaining device 9662

34. Tighten tension rod bolts or studs with 50 Nm (37 ftlb.). When doing so, observe the tightening sequence.

Assembling the crankcase.

408

einordnung

35. Tighten tension rod bolts onto the flywheel side to 50 Nm (37 ftlb.).

36. Fit new selflocking hexagon nut with washers and tighten to 50 Nm (37 ftlb.). Note The selflocking 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 cylindrical pin (5 x 18) for deformation before fitting and replace if necessary.

Assembling the crankcase.

409

einordnung

39. Mount new cylindrical pin so that it is flush. CAUTION Danger of injury The holding wrench must be in contact with the belt pulley when tightening.

40. Always replace fastening screw of the belt pulley. When tightening the belt pulley, a second person 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. Dimension X 1.0 0.2 mm 43. Turn belt pulley or the crankshaft to TDC, cylinder 1 or 4. 44. Subsequently fit piston or cylinder (see Serv. No.: 13 10 19)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Assembling the crankcase.

410

13 10 19 Removing and installing pistons (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 removing and installing cylinders)

411

einordnung Item A B Designation Assembly aid Explanation For positioning the restraining strap over the piston rings Restraining strap Restraining strap 9659 For mounting the pistons of cylinders 2 and 5. (Scope of delivery, 3 pieces) Piston ring restraining strap Refer to Workshop Equipment Manual, Chapter 2.4, No. 57 Pushing device Pushing device 9660 For mounting the bushings in the cylinder housing Spacer Spacing pieces 9651 Holder for cylinder Set of retaining nuts P 140 Assembly aid Assembly aid 9500/6 For preassembly of piston circlips in 9500/7 Plunger Plunger 9500/4 Assembly aid for piston pin Assembly sleeve For assembly of pistonpin circlips. 9500/7 circlip Assembly aid for piston pin Assembly aid 9500/3 For preassembly of the circlip circlips. in 9500/5 Grease for Orings on the cylinder Part No.: 999.917.788.00 mount bushings Special tool Assembly aid 9657

C D E F G H I J K

top of page

Removing pistons and cylinders

Tools

412

einordnung

Note: No. Designation 1 Cylinder 2 Bushings 3 Oring 104.00x2.00 Oring 110.00x2.50 Piston pin circlip Piston pin Qty. Removal 1 Identify, e.g. with cyl. 1 3 or 4 6 3 Identify with cyl. 1, 2, 3, 4, 5 or 6; assign to the corresponding piston 3 Installation Oil running surfaces Replace on principle, mount with special grease, do not twist Replace on principle, mount with special grease, do not twist Replace on principle, ensure correct seating

5 6

6 3

Lever out Assign to the corresponding piston

Removing pistons and cylinders

413

einordnung 7 Piston 3 Identify with cyl. 1, 2, 3, 4, 5 or 6, assign to the corresponding bushing, do not mark or clean piston with a sharp object. Oil piston shank

8 9

Piston rings Straight pins A8, 0x14 10 Cylinder base seal

9 1 1 Replace on principle, note installation position, "Top" faces the front

top of page

Removing pistons
Note 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 piston pin circlips with a suitable screwdriver and dispose of. Note The bushings should be marked accordingly

3. Knock bushing out of the cylinder. To do this, insert the pressure piece of the pushing device 9660 at the foot of the bushing and knock the bushing out with a plastic hammer. 4. Removing pistons 414

einordnung Remove Orings of cylinder and Orings of the bushings and dispose of. Assign bushings to the corresponding piston. top of page

Installing pistons and cylinders

Note Observe installation sequence The central pistons of cylinders 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. Mount individual pistons. Align the gaps of the piston rings offset by 120. CAUTION Risk of damage! Pay close attention to the oil scraper rings when tightening the restraining strap.

Installing pistons and cylinders

415

einordnung

2. Oil piston liberally. Mount commercially available restraining strap. Position special tool 9659/9 on top of the piston (piston junk).

3. Align restraining strap. The restraining strap lock should be aligned between the inlet valve recesses. Note The assembly sleeve 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 press the piston downwards and press the restraining strap downwards at the same time with the other hand. 5. Turn belt pulley or crankshaft clockwise until the connecting rods of cyl. 2 and 5 are at top dead centre.

Installing pistons and cylinders

416

einordnung 6. Mount the piston on the connecting rod. Push in oiled piston pin as far as it will go. Note A second person's help is recommended for pushing the circlip into the piston. Cover the opening in the crankcase below the piston so that the snap ring can not fall into the crankcase. After assembly, check that the snap ring is seated correctly via a visual inspection.

7. Push 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 serves as a guide into the piston pin. Push the snap ring into the piston pin retaining groove in the piston using the plunger. The circlip must audibly engage.

Position of the snap ring 8. Prepare the cylinders, outer bushings and piston for installation.

Insert new Orings into the cylinders. Grease Oring areas liberally.

Installing pistons and cylinders

417

einordnung

Mount new Orings onto the bushings. Grease Oring area liberally.

Mount outer bushings in the cylinders. 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 outer bushings with pushing device special tool 9660.

Installing pistons and cylinders

418

einordnung

View of the mounting tool

The outer bushings can also be pushed in with an hydraulic press if necessary.

Oil piston shank. Mount commercially available piston restraining strap. Push 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 upwards. If necessary turn the pistons in the bushing. Pull the pistons far enough out so that the piston pins can just be inserted.

Installing pistons and cylinders

419

einordnung

9. Mount the piston pins into the associated pistons from the inner side. The piston pin should only be inserted so far that the connecting rod 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 spacer special tool 9651 on the outer stud.

13. Push premounted cylinder onto the studs. Note

Installing pistons and cylinders

420

einordnung Check that the piston pin circlips are seated correctly!

14. Mount the piston pin and the piston pin circlip of the outer pistons from the inside (through the central cylinder opening). 15. After fitting the piston 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 Oring and grease liberally.

17. Position the bushing on the studs.

18. Fit pushing device 9660 on stud. Lay a plastic washer on the bushing and press the bushing into place on the piston by turning the handwheel.

Installing pistons and cylinders

421

einordnung

View of the special tool 19. Slowly turn belt pulley or the crankshaft clockwise until the central piston can no longer be seen in the gap between the cylinder and the crankcase. Then press the bushing into place with the pushing device until the restraining strap detaches from the piston shank.

20. Open the restaining strap lock using two screwdrivers and guide the restraining strap out between the crankcase 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 crankcase and cylinder. 24. Subsequently push the cylinder in the direction of the crankcase and move to its installation position. 25. To avoid the cylinder bank being pushed out when the horizontal cylinder bank is fitted or when the crankshaft is turned, secure cylinder bank with holder P 140.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing pistons and cylinders

422

13 19 21 Removing piston rings

Tools Removal top of page

Tools

Item Designation Special tool Piston ring pliers Gr. Commercially available; refer to Workshop 1 No. 58 Equipment Manual, Chapter 2.4, No.: 58

Explanation For the removing and fixing of the piston rings.

top of page

Removal
Note Combustion deposits on the piston crown are not to be removed mechanically!

13 19 21 Removing piston rings

423

einordnung

1 2 3 4 5 6

Prepare piston Remove pistons with piston ring pliers. Remove piston rings from piston ring pliers. Look for the gap of the oil scraper ring. Pull apart the oil scraper spring ring. Remove oil scraper spring ring.

Removal

424

einordnung

1. Place the removed pistons on a clean surface and look for the gap of the piston rings.

2. Remove the piston rings starting from the piston crown. In order to do this, place the middle point of the piston ring pliers into the gap of the relevant ring. The holding arms of the 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 piston ring pliers and remove the piston ring from the pliers.

4. Look for the gap of the oil scraper spring. In the ring groove of the oil scraper ring is another oil scraper spring. Look for the gap here. This is exactly opposite the tighter winding.

Removal

425

einordnung

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

Removal

426

13 19 23 Installing piston rings

Tools Installation top of page

Tools

Item

Designation Special tool Piston ring pliers Gr. 1 Commercially available; refer to Workshop No. 58 Equipment Manual, Chapter 2.4, No.: 58

Explanation For the removing and installing of piston rings

top of page

Installation

13 19 23 Installing piston rings

427

einordnung

1 2 3 4 5 6

Open oil scraper spring. Push together oil scraper spring. Align the gap of the oil scraper spring. Insert piston ring into the piston ring pliers. Install piston rings. Check that the piston ring is correctly seated and positioned.

1. Installation 428

einordnung Open oil scraper spring. In order to do this, pull apart the oil scraper spring at the gap. The gap can be recognised by the tighter winding of the spring.

2. Insert oil scraper spring. Insert the oil scraper spring into the lowest ring groove and then push together.

3. Align the gap of the oil scraper spring. The gap of the oil scraper spring must be installed offset by approx. 60 into the twist lock of the second ring groove.

4. Insert piston ring into the piston ring pliers. Make sure that, when installed, the designation of the piston rings is pointing in the direction of the piston crown.

5. Install piston rings. 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 where this can be placed over the pistons into ring groove 3. The gap of the oil scraper ring must be installed offset by exactly 180 into the gap of the oil scraper spring (or offset by 120 into the twist lock of the second ring groove). Make sure that the oil scraper spring is in the oil scraper ring. Then install the stepped taper faced ring (indicated by the lower recess on the outer edge). With the help of the piston ring pliers, insert the stepped taper faced ring into the second ring groove in such a way that the designation TOP is pointing towards the piston crown. The twist lock Installation 429

einordnung of the second ring groove must be between the gap of the stepped taper faced ring. Insert the taper faced ring into the ring groove in such a way that the designation TOP is pointing toward the piston crown.

6. Check that the piston ring is correctly seated and positioned. Make sure that the oil 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 piston crown. The highest piston ring must be installed in such a way that the designation TOP is pointing towards the piston crown. The gaps of the individual piston rings must always be offset by 120.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

430

13 48 37 Disassembling and assembling crankshaft

Tools Disassembling crankshaft Pressing ring knurled screw in and out Assembling crankshaft top of page

Tools

Item A A1 B

Designation of the special tool Retainer plate P209 a Panhead screws Snap ring pliers

Explanation SP No. 928.102.151.01 (3 ea.) Commercially available

13 48 37 Disassembling and assembling crankshaft

431

einordnung

No. Designation 1 Radial sealing ring 2 Bearing sleeve, bearing 8 3 Round seal 4 Radial sealing ring 5 Snap ring 6 Spacer ring 7 Timing gear

Qty. Removal 1 1 1 1 1 1 1

Installation Replace Replace

Woodruff key

Replace, do not fit twisted Replace Carry out insertion test Warm on heating plate, push on up to stop Check toothing Note reference number, paired with intermediate for wear, remove shaft, only install together, warm on heating plate, if necessary push on up to stop. The collar of the timing gear must point to bearing 7 Lift out with side Replace cutters and remove 432

Tools

einordnung 9 Connecting rod nut M9 x 1.25 12 Replace, tightening torque: Initial tightening: 30 Nm (22 ftlb.) Final tightening: 1 x 90 turn Note installation position and weight. Note classification or matching number to connectingrod bearing cap Replace Note matching number to connecting rod Replace Check Replace Replace Check for wear, carry out sounding test Check for presence and correct seat

10 Connecting rod

11 Connecting rod bearing shell half 12 Connectingrod bearing cap 13 Connecting rod bearing shell half 14 Conrod bolts 15 Main bearing shells of bearings 2 to 7 16 Main thrust bearing shells 17 Crankshaft

6 6 6 12 12 2 1

18 Roll pin 6.0 x 16

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Disassembling crankshaft
1. Remove tensioning sleeve (6 x 16) with a vicegrip wrench. 2. Clamp retaining plate P 209 a in the vice.

3. Fasten the crankshaft to the retaining plate with 3 panhead screws LO No. 928 102 151 01. 4. Loosen connecting rods with socket wrench insert M14 and remove.

Disassembling crankshaft

433

einordnung

5. Remove snap ring with snap ring pliers. 6. Remove spacer ring and timing gear with a conventional puller. 7. Raise Woodruff key with side cutters and remove. 8. Remove crankshaft from retaining plate. 9. Check crankshaft for shocks, cracks and wear. 10. Carry out sounding test. Note Before assembling the connecting rods, check without fail the elongation of the ring knurled screws. If the dimension X (38.3 mm) is exceeded, the connectingrod bolts must be replaced.

11. Check the connecting rods. Determine the length of the connectingrod bolts. Note In the case of the connectingrod version with a 3ring knurled screw, no replacement is possible. In this case, the entire connecting rod must be replaced. The 4ring knurled screw is available as a spare part.

Identifying the ring knurled screw

Identifying the ring knurled screw

434

einordnung

Note

The visual difference between the 3ring knurled screw and the 4ring knurled screw can only be detected when the screw is pressed out.

1. Identify the ring knurled screw. With the screw pressed in, measure the groove diameter. Object Measured value Screw type Diameter groove 1 > 7.9 mm 3ring knurled screw Diameter groove 1 < 7.9 mm 4ring knurled screw

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Pressing ring knurled screw in and out

Pressing ring knurled screw out

CAUTION In order to protect the conrod cover, always insert alumininum sheet strips at the sides into the vice.

Pressing ring knurled screw in and out

435

einordnung

1. Clamp the conrod cover into a machine vice. Press both 4ring knurled screws out at the same time.

Pressing ring knurled screw in

CAUTION In order to avoid damage to the joint face, always use an aluminium sleeve, e.g. from the special tool set P140 (retainer sleeves for cylinders).

1. Guide the new 4ring knurled screw by hand into the previous (old) toothing and then press it in up to the rest.

2. Reallocate the conrod cover and the connecting rod and lay to one side. top of page

Assembling crankshaft
1. Clean crankshaft thoroughly. 2. Rinse out oil bores with a hand pump and solvent naphtha several times. 3. With a visual inspection, check whether the oil ducts are blocked at the bearing surfaces and on the front face (aluminium stoppers). 4. Clamp crankshaft.

Pressing ring knurled screw out

436

einordnung

5. Lubricate the conrod journals with grease (Optimal Optipit) and mount the connecting rods on the crankshaft.

Note

The matching numbers of the conrods and the conrod bearing caps must all point to the same side. 6. Tighten conrod nuts.

7. After the tightening procedure, check the conrod bolt for twisting. 8. Insert and align new Woodruff key for timing gear. Note The collar of the timing gear must point to bearing 7!

Assembling crankshaft

437

einordnung As an assembly aid, remove the timing gear from the heat source e.g. with a piston restraining strap and quickly mount or push it into place on the journal. 9. Warm the timing gear to approx. 150 200C in an oil bath or on a heating plate and push it on to the crankshaft journal up to the stop. 10. Heat up the spacer ring in the same way and push it on up to the stop. 11. Mount snap ring. Note The snap ring must be inserted without play! The following snap rings are available: Part number Thickness (mm) 901.102.148.00 2.4 901.102.148.01 2.3 901.102.148.02 2.2 901.102.148.03 2.1 * most frequently used snap ring for first assembly Identification blank tempered blue* tempered yellow/brown black, gunmetal finish

12. Select the corresponding snap ring using an insertion test. 13. The opening of the snap ring should lie opposite the Woodruff key groove.

14. Knock the snap ring into the retaining groove with a blunt chisel. Location Thread Connecting rod nut M9 x 1.25 Tightening torque Nm (ftlb.) Initial tightening: 30 Nm (22 ftlb.); final tightening: 1 x 90 torque angle

Assembling crankshaft

438

einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Assembling crankshaft

439

13 73 37 Disassembling and assembling belt tensioner

Assembly note

No. Designation Qty. Removal 1 Hexagonhead bolt M10 x 4 60

Installation Insert the front right hexagonhead bolt (direction of travel) with Loctite 574. Tightening torque: 65 Nm (48 ftlb.)

2 3

Hexagonhead bolt M8 x 55 Hexagonhead bolt M8 x

1 2

13 73 37 Disassembling and assembling belt tensioner

440

einordnung 25 Hexagonhead bolt M8 x 55 Cover plate Deflection roller

4 5 6 7 8 9

1 1 1 1 1 1 1 1 1 1 1

Tightening torque 23 Nm (17 ftlb.) Check for smooth running or roughness before undoing Check, replace if necessary Tightening torque: 23 Nm (17 ftlb.) Check for smooth running or roughness before undoing Check, replace if necessary Replace

Spacer Oring Hexagonhead bolt M8 x 55 10 Cover plate 11 Deflection roller 12 Spacer 13 Oring 14 Hexagonhead bolt (microencapsulated) M10 x 30 15 Tensioning roller

Undo at the hexagon (wrench size 24) and simultaneously counter at the hexagonhead bolt

Tightening torque: 60 Nm (44 ftlb.) Counter at the hexagonhead bolt when tightening (wrench size 15)

16 Spacer ring 17 Threaded sleeve with hexagon (wrench size 24) 18 Cover plate 19 Transmission lever with hexagon (wrench size 15mm) 20 Panhead screw M6 x 16 21 Tensioning lever 22 Dust cap 23 Panhead screw M8 x 16 24 Tensioning element 25 Dust cap 26 Bearing sleeve 27 Bearing sleeve 28 Dowel sleeve M6 x 10 29 Bracket

1 1 1 1

Thread on to tensioning lever (No. 21). See Assembly note Tightening torque: 9.7 Nm (7 ftlb.) Fit in correct position; grease in area of bearing Tightening torque: 23 Nm (17 ftlb.)

1 1 1 2 1 1 1 1 2 1 Drive out of the tensioning element with a drift ( 5)

Grease with Optimol Optipit grease Grease with Optimol Optipit grease

13 73 37 Disassembling and assembling belt tensioner

441

einordnung

top of page

Assembly note

1. Thread transmission lever on to tensioning lever. Tightening torque: 65 Nm (48 ftlb.)

2. Insert the front right hexagonhead bolt on the bracket with Loctite 574.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Assembly note

442

13 78 19 Removing and installing drive belt (engine installed)

Removal overview of the drive belt (engine installed) Remove drive belt Installation overview of the drive belt (engine installed) Install drive belt

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Removal overview of the drive belt (engine installed)

13 78 19 Removing and installing drive belt (engine installed)

443

einordnung

1 2 3 4 5

Remove air cleaner assembly Loosen servo pump wheel Relieve drive belt Remove servo pump wheel Remove drive belt

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Remove drive belt

Removal overview of the drive belt (engine installed)

444

einordnung

1. Remove air cleaner assembly Remove the complete air cleaner assembly. a. Undo hexagonhead bolt M6 x 34. b. Undo the hose clamp on the throttle body. c. Pull off plug from hot film mass 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 hexagonhead bolts on the servo pump by approx. one half turn.

3. Relieve drive belt Relieve drive belt. To do this, turn the tensioning roller clockwise and simultaneously remove the belt from the drive pulleys.

Remove drive belt

445

einordnung

4. Remove servo pump wheel Note Only remove the servo pump wheel when the drive belt 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 installed)

Installation overview of the drive belt (engine installed)

446

einordnung

1 2 3 4 5

Fit drive belt Position servo pump wheel Tension drive belt Tighten fastening screws on servo pump Install air cleaner assembly

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Installation overview of the drive belt (engine installed)

447

einordnung

Install drive belt

1. Fit drive belt Fit the belt onto the drive wheels.

2. Position servo pump wheel a. Put on the servo pump wheel together with the drive belt. b. Slightly tighten the three fastening screws on 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 7 in clockwise direction and simultaneously fit the drive belt on the deflection roller 8 . d. Then slowly relieve. To do this, turn the tensioning roller slowly anticlockwise.

Install drive belt

448

einordnung

4. Tighten fastening screws on servo pump Tighten the fastening screws of the servo pump drive wheel. Tightening torque: 23 Nm (17 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 hexagonhead bolt to 10 Nm (7.5 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Install drive belt

449

15 03 21 Removing camshaft housing removed

Tools Component overview and tightening torques Removing the camshaft housing top of page

engine

Tools

Item Designation of the tool A Special tool holding wrench 9653/1 B Special tool holding wrench 9653

C Commerically available multipletooth socket wrench insert M12 D Commercially available torque angle wrench Gr. 2.4; Workshop Equipment Manual, No. 88 716/20

Remarks For countering the exhaust camshaft Gr. 2.2.2 ; Workshop Equipment Manual For countering the inlet camshaft Gr. 2.2.2 ; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual, No. 31

top of page

Component overview and tightening torques

15 03 21 Removing camshaft housing

engine removed

450

einordnung

No. Designation 1 Closure cap, green 2 Cover with 3 hexagonhead bolts M6 x 20 and Oring 3 Oil pump with 3 hexagonhead bolts M6 x 35 and Oring 4 Hexagonhead bolt M 6 x 25 5 Holder for hydraulic valve 6 Hydraulic valve for valve lift adjustment

Qty. Removal 2 1

Installation Replace; insert dry Replace Oring; tightening torque 10 Nm (7.5 ftlb.) Replace Oring; tightening torque 10 Nm (7.5 ftlb.) 10 Nm (7.5 ftlb.)

2 1 1

Pull out carefully, use special Special tool Gr. 2.2.2; Workshop tool relay puller 9235 if Equipment Manual necessary

Component overview and tightening torques

451

einordnung 6a Oring for hydraulic valve 1 7 8 Hexagonhead bolt M6 x 1 70 Hexagonhead bolt M 6 x 14 35 Hexagonhead bolt M 6 x 2 40 (only pages 4 6) Camshaft housing lid 1 1 2 hexagonhead bolts M6 Replace Oring, oil lightly if necessary (engine oil) 10 Nm (7.5 ftlb.) (Pages 4 6 only 12 M6 x 35) 10 Nm (7.5 ftlb.) Fastening holder for oil container onto camshaft housing cover 10 Nm (7.5 ftlb.)

10 Chain tensioner

11 Guide rail with 3 1 hexagonhead bolts M6 x 25 12 Panhead screw, drive 1 plate and plate for sprocket wheel of exhaust camshaft

Clean sealing surface; sealant: Drei Bond or Loctite 5900 Observe identification! 10 Nm (7.5 ftlb.) 10 Nm (7.5 ftlb.)

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 Counter with special tool holding wrench 9653

13 Hexagonhead bolt M12 x 1.5 x 120 with washer for actuating element of inlet camshaft 14 Chain sprocket of exhaust camshaft 15 Actuating element for inlet camshaft 16 Screw M5 x 10 microencapsulated (hexagon socket) 17 Oil guide housing

1 1 3

Observe left and right side (coating)

Replace screw; contact surfaces must be completely free of grease and oil. Counter with special tool 9653/1; tightening torque 30 Nm (22 ftlb.) and 1 x 90 torque angle Replace screw; counter with special tool 9653; tightening torque 30 Nm (22 ftlb.) and 170 torque angle Contact surfaces must be completely free of grease and oil. Left stop for setting timing Replace screws, tightening torque 7 Nm (5.0 ftlb.)

18 Hexagonhead bolts M6 x 12 30 (10.9) 19 Camshaft bearing cap 6 20 Hexagonhead bolts M6 x 4 30 (10.9) 21 Thrust bearing cover 2 22 Exhaust camshaft 23 Inlet camshaft 1 1

Screws can fall into the crankcase! Use solenoid socket wrench insert if necessary Do not confuse left and right part Unscrew screws from the inside Unscrew carefully!

Observe height! Tighten in specified sequence (description); 13 Nm (9.5 ftlb.) Grease lightly; observe matching number! 13 Nm (9.5 ftlb.) Grease lightly; observe matching number! Observe identification on the rotor! (cylinder bank allocation)

Unscrew carefully!

Component overview and tightening torques

452

einordnung Observe identification on the rotor! (cylinder bank allocation) Oil lightly, pay attention to cleanliness! Oil lightly, pay attention to cleanliness! Tightening torques: Initial tightening 23 Nm (17 ftlb.); final tightening 28 Nm (21 ftlb.)

24 Flatbase tappets of 6 exhaust camshaft 25 Operating plunger of inlet 6 camshaft 26 Camshaft housing with 18 1 hexagonhead bolts M8 x 50 (10.9)

Do not exchange Do not exchange If hexagonhead bolts of strength class 8.8 were installed, exchange these for bolts of strength class 10.9.

top of page

Removing the camshaft housing

The following prelimiminary work must be carried out: Remove engine 100119 Removing and installing engine . Remove rear muffler. Remove the oil container 175219 Removing and installing oil container . Remove generator 272219 Removing and installing threephase generator . Remove coolant guide housing. 1. Cylinder bank 1 3: Undo fuel 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. Remove electrical plug of the ignition coils, unscrew 2 cylinder screws (hexagon socket) M6 x 25 of each and pull ignition coils out of sparkplug recess. 4. Remove 2 closure caps (green, plastic) between camshaft housing cover and cylinder head (clutch side). To do so, puncture the closure cap in the middle and lever out using a small slotted screwdriver.

5. Remove oil extraction pump and closure cap. The oil extraction pump flange must be held with a wrench when the oil line on the pump is loosened. Subsequently unscrew the three fastening screws of the oil extraction pump and the three fastening screws of the closure cap, then lever off the two components. 6. Remove solenoid hydraulic valve for valve lift adjustment. To do so, remove plug, unscrew both hexagonhead bolts M6 x 25 and remove with the holder. Subsequently remove the valve.

Removing the camshaft housing

453

einordnung

7. Remove camshaft housing cover. Unscrew the 15 hexagonhead 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 which is to be worked on must be positioned to overlapping TDC so that the camshaft can 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 inlet camshaft of cylinder 4 point away from eachother (each points towards the cylinder head outer wall) Figure 8.2 .

Figure 8.1: Overlapping TDC of cylinder 1 1 Exhaust camshaft 2 Inlet camshaft

Figure 8.2: Overlapping TDC of cylinder 4 2 Inlet camshaft 1 Exhaust camshaft

Removing the camshaft housing

454

einordnung

9. Remove chain tensioner. To do this, 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 short guide rail between the camshaft sprockets and remove the guide rail. Note

11. Remove camshaft sprockets. The timing chain must not be loaded when the 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 sprocket wheel of the exhaust camshaft must be countered using speical tool holding wrench 9653/1 . Note Only remove oil guide housing from the camshaft if the camshaft has to be replaced! The panhead screws of the oil guide housing can fall into the crankcase when unscewing, the use of a magnetic socket wrench insert is therefore recommended.

Removing the camshaft housing

455

einordnung

The oil guide housing of cylinder 1 3 and 4 6 differ in height.

12. Remove oil guide housing. Heat the three hexagon socket head bolts using a hotair gun, unscrew and remove the housing. The fastening screws are microencapsulated and therefore must be replaced.

13. Remove camshaft bearing cap. To do so, uniformly unscrew the hexagonhead bolts of the relevant bearing covers from the inside. Remove the bearing covers in the specified order.

14. Remove camshaft bearing covers. Lift the bearing covers up and off. The bearing covers must not be confused.

Removing the camshaft housing

456

einordnung

15. Remove thrust bearing cover. Unscrew the hexagonhead bolts and remove the thrust bearing cover up and off. 16. Lift camshafts up and out. WARNING Do not confuse the flatbase tappets. The flatbase tappets have been run in in their housing. Therefore, they must not be interchanged or soiled.

17. Remove the flatbased tappets. Pull the flatbased tappets upwards out of the camshaft housing. In order to avoid confusing the individual flatbased tappets, they should be placed on a prepared sheet of paper as shown in the diagram.

18. Remove the camshaft housing. Unscrew and remove the 18 hexagonhead bolts in the order specified. Then remove the camshaft housing.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing the camshaft housing

457

15 03 23 Installing camshaft housing

Refer to tools and tightening torques in Chapter "Removing camshaft housing"!

1. Replace seals. Replace the seals between the chain box/camshaft housing and the cylinder head/camshaft housing seal. The embossed recesses in the seal must face the cylinder head. 2. Place the camshaft housing in position. Carefully put the camshaft housing on in a staight line. When doing so, make sure that the flatbased 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 hexagonhead bolts. The bolts are tightened in two stages in the order specified. Initial tightening: 23 Nm (17 ftlb.) Final tightening: 28 Nm (21 ftlb.)

4. Insert flatbased tappets. Spread a thin coat of clean engine oil on the flatbase tappets. Do not interchange the flatbase tappets. In the case of the flatbase tappets for the inlet camshaft, make sure that the feather keys are positioned in the grooves in the flatbase tappet housing. 5. 15 03 23 Installing camshaft housing 458

einordnung Subsequently install the camshafts => Removing and installing camshafts &ndash; engine removed.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

15 03 23 Installing camshaft housing

459

15 05 02 Checking camshafts (timing) removed

Tools Checking camshafts top of page

engine

Tools

Item Designation of the tool A Special tool holding wrench 9653/1 B Special tool holding wrench 9653

C Commerically available multipletooth socket wrench insert M12 D Commercially available torque angle wrench Gr. 2.4; Workshop Equipment Manual, No. 88 716/20 15 05 02 Checking camshafts (timing) engine removed

Remarks For countering the exhaust camshaft Gr. 2.2.2 ; Workshop Equipment Manual For countering the inlet camshaft Gr. 2.2.2 ; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual, No. 31

460

einordnung

Item A B

Special tool designation Auxiliary chain tensioner 9401

Remarks For removing play from the timing drive mechanism Adjustment device 9661 with holding keys 9661/1 In order to fix the camshafts in the correct position

top of page

Checking camshafts
The following prelimiminary work must be carried out: Remove engine 100119 Removing and installing engine . Remove rear muffler. Remove the oil container 175219 Removing and installing oil container . Remove generator 272219 Removing and installing threephase generator . Remove coolant guide housing. 1. Cylinder bank 1 3: Undo fuel 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 coils. Remove electrical plug of the ignition coils, unscrew 2 cylinder screws (hexagon socket) M6 x 25 of each and pull ignition coils out of sparkplug recess. 4. Remove 6 spark plugs 032000 Removing spark plugs . Tools 461

einordnung

5. Remove oil extraction pump and closure cap. The oil extraction pump flange must be held with a wrench when the oil line on the pump is loosened. Subsequently unscrew the three fastening screws of the oil extraction pump and the three fastening screws of the closure cap, then lever off the two components. 6. Remove solenoid hydraulic valve for valve lift adjustment. To do so, remove plug, unscrew both hexagonhead bolts M6 x 25 and remove with the holder. Subsequently remove the valve.

7. Remove camshaft housing cover. Unscrew the 15 hexagonhead 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 two hexagonhead bolts M6 on each chain tensioner cover and remove the covers with the chain tensioner. Subsequently screw on both auxiliary chain tensioners and then apply pretension using the hexagonhead bolt until the first ring on the piston just disappears from view.

9. Fit dial gauge. A dial gauge is affixed to the first cylinder on cylinder bank 1 3 using the universal dial gauge holder. Extend the probe of the dial gauge until it is certain that measurement on the piston crown is possible. Checking camshafts 462

einordnung 10. 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 (in operating direction) until the maximum defection (reversing point) is attained on the dial gauge. The cams of 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 cylinder 1 1 Exhaust camshaft 2 Inlet camshaft

Figure 10.2: Overlapping TDC of cylinder 4 2 Inlet camshaft 1 Exhaust camshaft Note Camshaft adjusting element must be positioned to the lefthand stop! Use special tool holding wrench 9653 !

Checking camshafts

463

einordnung 11. Turn camshaft adjusting element of the inlet camshafts to its left stop. Use special tool holding wrench 9653 to turn the actuating element of the inlet camshaft counterclockwise until it meets the stop. Note Tighten the screws for the adjustment device only slightly. It must be possible to move the frame easily by hand.

12. Fit adjustment devices. Use two screws to fasten the frame of both staking tools 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 their identification and then fasten them with two fastening screws to prevent them from dropping.

Adjustment device of cylinder bank 4 6 Note If the timing setting is correct, it must be possible to insert the appropriate holding key 9661/1 into the slot of the camshaft without using much force. Set the timing if incorrect => Setting camshafts (timing) &ndash; engine removed

Checking camshafts

464

einordnung

Correctly set camshafts 14. Turn the engine on the belt pulley of the crankshaft by 360 clockwise so that the second cylinder side can be checked. (Observe maximum defection of dial gauge indicator or TDC position!). Note Camshaft adjusting element must be positioned to the lefthand stop! Use special tool holding wrench 9653 ! 15. Position the holding keys 9661/1 of the corresponding cylinder bank. The holding keys must slide easily into the camshaft slot. 16. Remove the adjustment devices and the dial gauge. 17. Remove the auxiliary chain tensioner. To do this, relieve the auxiliary chain tensioner and loosen the two fastening screws. 18. Reinstall chain tensioner. Insert the chain tensioner into the chain housing in accordance with its identification, then fit the chain tensioner cover with a new seal. Tighten the hexagonhead 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 housing cover and tighten the 15 fastening screws from the inside with tightening torque. Tightening torque of the hexagonhead bolt M6 (8.8) 10 Nm (7.5 ftlb.) 20. Install solenoid hydraulic valve for valve lift adjustment. Put on holder with both hexagonhead bolts M6 x 25 and tighten the screws with tightening torque. Tightening torque of the hexagonhead bolt M6 (8.8) 10 Nm (7.5 ftlb.) 21. Fit the closure cap and the oil extraction pump with new Orings. Tighten the hexagonhead bolts: 3 M6 x 20 for the closure cap and 3 M6 x 35 for the oil extraction pump to tightening torque. Tightening torque of the hexagonhead bolt M6 (8.8) 10 Nm (7.5 ftlb.) 22. Fit four new closure caps (green) for camshaft housing cover in dry state. 23. Install spark plugs 032000 Installing spark plugs .

Checking camshafts

465

einordnung Tightening torque of new spark plug 30 Nm (22 ftlb.); used spark plugs 25 Nm (19 ftlb.) 24. Install ignition coils. Insert ignition coils in sparkplug recess. Position 2 panhead screws (hexagon socket) M6 x 25 and tighten with tightening torque. Connect cable plug. Tightening torque of panhead screw M6 10 Nm (7.5 ftlb.) Note Replace fastening nuts for holder of turbocharger! 25. Cylinder bank 1 3: Install fuel collection pipe with 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.) 27. Install coolant guide housing. 28. Install generator 272219 Removing and installing threephase generator . 29. Install the oil container 175219 Removing and installing oil container . Note Replace fastening nuts for flange of turbocharger rear mufflers! 30. Install rear mufflers. Tightening torque of fastening nut M8 25 Nm (19 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Checking camshafts

466

15 05 16 Setting camshafts (timing)

Tools Setting the camshafts (timing) top of page

engine removed

Tools

Item Designation of the tool A Special tool holding wrench 9653/1 B Special tool holding wrench 9653

C Commerically available multipletooth socket wrench insert M12 D Commercially available torque angle wrench Gr. 2.4; Workshop Equipment Manual, No. 88 716/20

Remarks For countering the exhaust camshaft Gr. 2.2.2 ; Workshop Equipment Manual For countering the inlet camshaft Gr. 2.2.2 ; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual, No. 31

15 05 16 Setting camshafts (timing)

engine removed

467

einordnung

Item A B

Special tool designation Auxiliary chain tensioner 9401

Remarks For removing play from the timing drive mechanism Adjustment device 9661 with holding keys 9661/1 In order to fix the camshafts in the correct position

top of page

Setting 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 undo the screw connection, the camshaft adjusting elements (inlet shaft) must be countered using special tool holding wrench 9653 and the sprocket wheels (exhaust shaft) must be countered using special tool holding wrench 9653/1 .

Tools

468

einordnung 2. Fit auxiliary chain tensioner for both cylinder banks. Unscrew two hexagonhead bolts M6 on each chain tensioner cover and remove the covers with the chain tensioner. Subsequently screw on both auxiliary chain tensioners and then apply pretension using the hexagonhead bolt until the first ring on the piston just disappears from view.

3. Fit dial gauge. A dial gauge is affixed to the first cylinder on cylinder bank 1 3 using the universal dial gauge holder. Extend the probe of the dial gauge until it is certain that measurement 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 (in operating direction) until the maximum defection (reversing point) is attained on the dial gauge. The cams of the 1st cylinder point towards each other Figure 4.1 , the cams of the 4th cylinder point away from each other (each points towards cylinder head outer wall) 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 overlapping of cylinder 4 2 Inlet camshaft 1 Exhaust camshaft

Setting the camshafts (timing)

469

einordnung Note Camshaft adjusting element must be positioned to the lefthand stop! Use special tool holding wrench 9653 !

5. Turn camshaft adjusting element of the inlet camshafts to its left stop. Use special tool holding wrench 9653 to turn the actuating element of the inlet camshaft counterclockwise until it meets the stop. Note Tighten the screws for the 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 (clutch side) on the sealing surface for the valve cover. Tighten screws by hand only. 7. Insert holding keys. Insert the holding keys 9661/1 into the frame according to their identification and then fasten them with two fastening screws to prevent them from dropping.

Adjustment device of cylinder bank 1 3

Setting the camshafts (timing)

470

einordnung

Adjustment device of cylinder bank 4 6

8. Set camshafts on cylinder side 1 3 (cams of both camshafts point towards each other on cylinder 1). To do this, use a suitable openended wrench (a/f 30) to turn the hexagon on the camshafts until the holding key of the staking tool easily enters the slot of the camshaft. Fix holding keys with both hexagonhead bolts.

Correctly set camshafts Note Camshaft adjusting element must be positioned to the lefthand 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 the inlet and exhaust camshafts with initial tightening of 30 Nm (22 ftlb.). When doing so, counter the sprockets using the appropriate special tools holding wrench 9653 or holding wrench 9653/1 . Subsequently remove the holding keys 9661/1 and tighten the exhaust camshaft with a 90 torque angle and the inlet camshaft with a 170 torque angle. Counter camshafts with the appropriate special tools. 10. Setting the camshafts (timing) 471

einordnung Turn the engine on the belt pulley of the crankshaft by 360 clockwise so that the second cylinder side can be set. (Observe maximum defection of dial gauge indicator or TDC position!). 11. Set cylinder side 4 6 in the same way as side 1 3 (cams of both camshafts on cylinder 4 point away from each other). Note Camshaft adjusting element must be positioned to the lefthand stop! Use special tool holding wrench 9653 ! 12. Tighten sprocket wheels. Check whether the actuating element of the inlet camshaft is still on the left stop. Subsequently tighten the sprockets of the inlet and exhaust camshafts with initial tightening of 30 Nm (22 ftlb.). When doing so, counter the sprockets using the appropriate special tools holding wrench 9653 or holding wrench 9653/1 . Subsequently remove the holding keys 9661/1 and tighten the exhaust camshaft with a 90 torque angle and the inlet camshaft with a 170 torque angle. Counter camshafts with the appropriate special tools. 13. Check the timing. Turn engine on belt pulley of crankshaft clockwise by 720. 14. Refit the holding keys and check the timing on both cylinder sides. 15. Remove the adjustment devices and the dial gauge if timing is set correctly, otherwise repeat the setting. 16. Remove 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 accordance with its identification, then fit the chain tensioner cover with a new seal. Tighten the hexagonhead bolts M6 to 10 Nm (7.5 ftlb.). 18. Clean sealing surface for the camshaft housing cover.

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 housing cover and tighten the 15 fastening screws from the inside with tightening torque. Tightening torque of hexagaonhead bolt M6 (8.8) 10 Nm (7.5 ftlb.) 20. Install solenoid hydraulic valve for valve lift adjustment. Put on holder with both hexagonhead bolts M6 x 25 and tighten the screws with tightening torque. Tightening torque of hexagonhead bolt M6 (8.8) 10 Nm (7.5 ftlb.) 21. Fit the closure cap and the oil extraction pump with new Orings. Tighten the hexagonhead bolts: 3 M6 x 20 for the closure cap and 3 M6 x 35 for the oil extraction pump to tightening torque. Tightening torque of hexagonhead bolt M6 (8.8) 10 Nm (7.5 ftlb.) 22. Fit four new closure caps (green) for camshaft housing cover in dry state. 23. Install spark plugs 032000 Installing spark plugs . Tightening torque of new spark plug 30 Nm (22 ftlb.); used spark plugs 25 Nm (19 ftlb.) 24. Setting the camshafts (timing) 472

einordnung Install ignition coils. Insert ignition coils in sparkplug recess. Position 2 panhead screws (hexagon socket) M6 x 25 and tighten with tightening torque. Connect cable plug. Tightening torque of panhead screw M6 10 Nm (7.5 ftlb.) Note Replace fastening nuts for holder of turbocharger! 25. Cylinder bank 1 3: Install fuel collection pipe with 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.) 27. Install coolant guide housing. 28. Install generator 272219 Removing and installing threephase generator . 29. Install the oil container 175219 Removing and installing oil container . Note Replace fastening nuts for flange of turbocharger rear mufflers! 30. Install rear mufflers. Tightening torque of fastening nut M8 25 Nm (19 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Setting the camshafts (timing)

473

15 05 19 Removing and installing camshafts removed

Tools Component overview and tightening torques Removing camshafts Installing camshafts top of page

engine

Tools

Item Designation of the tool A Special tool holding wrench 9653/1 B Special tool holding wrench 9653 C Commerically available multipletooth socket wrench insert M12 15 05 19 Removing and installing camshafts

Remarks For countering the exhaust camshaft Gr. 2.2.2 ; Workshop Equipment Manual For countering the inlet camshaft Gr. 2.2.2 ; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual, No. 31

engine removed

474

einordnung D Commercially available torque angle wrench Gr. 2.4; Workshop Equipment Manual, No. 88 716/20

top of page

Component overview and tightening torques

No. 1 2

Designation Closure cap, green Cover with 3 hexagonhead bolts M6 x 20 and Oring Oil pump with 3

Qty. 2 1

Removal

Installation Replace; insert dry Replace Oring; tightening torque 10 Nm (7.5 ftlb.) Replace Oring;

Tools

475

einordnung hexagonhead bolts M6 x 35 and Oring Hexagonhead bolt M 6 x 25 2 Holder for hydraulic valve 1 Hydraulic valve for valve lift 1 adjustment Oring for hydraulic valve 1 tightening torque 10 Nm (7.5 ftlb.) 10 Nm (7.5 ftlb.) Pull out carefully, use special tool Special tool Gr. relay puller 9235 if necessary 2.2.2; Workshop Equipment Manual Replace Oring, oil lightly if necessary (engine oil) 10 Nm (7.5 ftlb.) (Pages 4 6 only 12 M6 x 35) 10 Nm (7.5 ftlb.) Fastening holder for oil container 10 Nm (7.5 ftlb.) onto camshaft housing cover Clean sealing surface ; sealant : Drei Bond or Loctite 5900 2 hexagonhead bolts M6 Observe identification! 10 Nm (7.5 ftlb.) 10 Nm (7.5 ftlb.) Replace screw; contact surfaces must be completely free of grease and oil. Counter with special tool 9653/1; tightening torque 30 Nm (22 ftlb.) and 1 x 90 torque angle Counter with special tool holding Replace screw; wrench 9653 counter with special tool 9653; tightening torque 30 Nm (22 ftlb.) and 170 torque angle Observe left and right side Contact surfaces (coating) must be completely free of grease and oil. Left stop for setting timing Screws can fall into the Replace screws, crankcase! Use magnetic socket tightening torque 7 wrench insert if necessary Nm (5.0 ftlb.) Do not confuse left and right part Observe height! 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 476

4 5 6

6a

7 8 9

Hexagonhead bolt M6 x 70 Hexagonhead bolt M 6 x 35 Hexagonhead bolt M 6 x 40 (only pages 4 6) Camshaft housing lid

1 14 2 1

10

Chain tensioner

11 12

Guide rail with 3 1 hexagonhead bolts M6 x 25 Panhead screw, drive plate 1 and plate for sprocket wheel of exhaust camshaft

13

Hexagonhead bolt M12 x 1.5 1 x 120 with washer for actuating element of inlet camshaft

14

Chain sprocket of exhaust camshaft

15 16

17

Actuating element for inlet camshaft Screw M5 x 10 microencapsulated (hexagon socket) Oil guide housing

1 3

Component overview and tightening torques

einordnung 18 Hexagonhead bolts M6 x 30 12 (10.9) Unscrew screws from the inside Tighten in specified sequence (description); 13 Nm (9.5 ftlb.) Grease lightly; observe matching number! 13 Nm (9.5 ftlb.) Grease lightly; observe matching number! Observe identification on the rotor! (Cylinder bank allocation) Observe identification on the rotor! (Cylinder bank allocation)

19

Camshaft bearing cap

Unscrew carefully!

20 21

Hexagonhead bolts M6 x 30 4 (10.9) Thrust bearing cover 2

Unscrew carefully!

22

Exhaust camshaft

23

Inlet camshaft

24

Camshaft housing

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Removing camshafts
The following prelimiminary work must be carried out: Remove engine 100119 Removing and installing engine . Remove rear muffler. Remove the oil container 175219 Removing and installing oil container . Remove generator 272219 Removing and installing threephase generator . Remove coolant guide housing. 1. Cylinder bank 1 3: Undo fuel 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. Remove cable plug of the ignition coils, unscrew 2 cylinder screws (hexagon socket) M6 x 25 of each and pull ignition coils out of sparkplug recess. 4. Remove 2 closure caps (green, plastic) between camshaft housing cover and cylinder head (clutch side). To do so, puncture the closure cap in the middle and lever out using a small slotted screwdriver.

Removing camshafts

477

einordnung

5. Remove oil extraction pump and closure cap. The oil extraction pump flange must be held with a wrench when the oil line on the pump is loosened. Subsequently unscrew the three fastening screws of the oil extraction pump and the three fastening screws of the closure cap, then lever off the two components. 6. Remove solenoid hydraulic valve for valve lift adjustment. To do so, remove plug, unscrew both hexagonhead bolts M6 x 25 and remove with the holder. Subsequently remove the valve.

7. Remove camshaft housing cover. Unscrew the 15 hexagonhead 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 which is to be worked on must be positioned to overlapping TDC so that the camshaft can 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 inlet camshaft of cylinder 4 point away from eachother (each points towards the cylinder head outer wall) Figure 8.2 .

Figure 8.1: Overlapping TDC of cylinder 1 1 Exhaust camshaft 2 Inlet camshaft

Removing camshafts

478

einordnung

Figure 8.2: Overlapping TDC of cylinder 4 2 Inlet camshaft 1 Exhaust camshaft

9. Remove chain tensioner. To do this, 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 short guide rail between the camshaft sprockets and remove the guide rail. Note

Removing camshafts

479

einordnung 11. Remove camshaft sprockets. The timing chain must not be loaded when the 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 sprocket wheel of the exhaust camshaft must be countered using speical tool holding wrench 9653/1 . Note Only remove oil guide housing from the camshaft if the camshaft has to be replaced! The panhead 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 cylinder 1 3 and 4 6 differ in height.

12. Remove oil guide housing. Heat the three hexagon socket head bolts using a hotair gun, unscrew and remove the housing. The fastening screws are microencapsulated and therefore must be replaced.

13. Remove camshaft bearing cap. To do so, uniformly unscrew the hexagonhead bolts of the relevant bearing covers from the inside. Remove the bearing covers in the specified order.

Removing camshafts

480

einordnung

14. Remove camshaft bearing covers. Lift the bearing covers up and off. The bearing covers must not be confused.

15. Remove thrust bearing cover. Unscrew the hexagonhead bolts and remove the thrust 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 housing of cylinder banks 1 3 and 4 6 The following assembly is only required if the oil guide housing has been disconnected from the camshaft when removing!

Installing camshafts

481

einordnung

1. Mount the oil guide housing. Fit the oil guide housing above the three sealing rings of the inlet camshaft. The oil guide housing should be lightly oiled for this purpose. Press the sealing rings together by hand and push the oil guide housing over them.

Prefitted oil guide housing 2. Move engine to TDC. Turn 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 allocated via the identification on the rotor cover. The last three digits indicate the cylinder bank in which the respective camshaft is installed.

Position of camshaft designation WARNING Risk of damage! The bearing locations must not be oiled. Only grease is permissible.

Installing camshafts

482

einordnung 3. Insert camshafts. The bearing locations of the camshafts must be lightly greased before installation. Place the timing chain over the camshafts when inserting the camshafts. 4. Position camshafts. It must be ensured that the camshafts are correctly positioned in the bearing locations. The camshafts must be turned such that the cams of the first cylinder of the bank are located at overlapping TDC. This means that the cams of the inlet and exhaust shaft of the first cylinder point towards each other Figure 4.1 , the cams of the fourth 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 overlapping of cylinder 4 2 Inlet camshaft 1 Exhaust camshaft 5. Fit bearing cover. Fit the six small bearing covers so that the bearing location numbers on the camshaft housing and on the bearing location face each other. Make sure that the matching numbers on the bearing covers and on the camshaft housing are identical. Position the hexagonhead bolts M6 x 30.

6. Fit thrust bearing cover. Place the large thrust bearing cover onto both camshafts and tighten the hexagonhead bolts M6 x 30 slightly. Installing camshafts 483

einordnung

7. Tighten bearing cover. Tighten the hexagonhead bolts M6 x 30 of the bearing cover uniformly to tightening torque in the specified sequence. Tightening torque of the bearing cover screws (10.9) 13 Nm (10 ftlb.)

8. Tighten oil guide housing. Replace the three panhead screws M5 x 10 (microencapsulated) and tighten to tightening torque. Tightening torque of M5 panhead screws (8.8) 7 Nm (5 ftlb.) 9. Tighten the hexagonhead bolts M6 x 30 for the thrust bearing cover to tightening torque. Tightening torque of the thrust bearing screws M6 (10.9) 13 Nm (10 ftlb.) Note The camshaft adjusting elements must be positioned to the lefthand stop! Use special tool holding wrench 9653 ! The hexagonhead bolts M12 for the actuating element of the inlet camshaft is to be replaced! 10. Place camshaft adjusting element onto inlet camshaft. Lay the timing chain onto the chain sprocket of the camshaft adjusting element and place the adjusting element onto the inlet camshaft. Tighten the new hexagonhead screw M12 x 120 by hand. Turn the camshaft adjusting element to the left stop using special tool holding wrench 9653 . New chain sprockets for the exhaust camshafts (left and right part) have been in use as of May 2001. The identical chain sprocket remains an original Porsche part observe part numbers!

Identification of the sprocket wheels Installing camshafts 484

einordnung Left wheel with coating and part number (identification "left" on rear side) Right wheel with part number and identification "right" (coating on rear side) Note The contact surfaces of the sprocket wheels and camshaft flange (exhaust side) must be completely free of oil and grease! The coated surface points towards the camshaft flange! The drive plates for the oil extraction pumps differ in height. The drive plate on cylinder bank 1 3 is higher! The internal serration screw M12 must be replaced!

11. Fit exhaust camshaft wheel. Clean mounting surface of the sprocket and of the exhaust camshaft and remove all oil and grease. The inscription left must be visible for cylinder bank 13, and right must be visible for cylinder bank 46. Push on the sprocket. Push on the drive plate for the oil extraction pump and tighten the new internalserration screw by hand. Observe height of drive plates of cylinder banks 1 3 and 4 6!

12. Mount the guide rail between the sprocket wheels. Tighten the three M6 x 25 hexagonhead bolts with the correct tightening torque. Tightening torque of the hexagonhead bolts M6 (10.9) 13 Nm (10 ftlb.) 13. Set the timing. => Setting camshafts (timing) &ndash; engine removed . Note The following work can be carried out only after the timing has been adjusted! 14. Reinstall chain tensioner. Insert the chain tensioner into the chain housing in accordance with its identification, then fit the chain tensioner cover with a new seal. Tighten the hexagonhead bolts M6 to Installing camshafts 485

einordnung 10 Nm (7.5 ftlb.). 15. Clean sealing surface for the camshaft housing cover.

16. 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 housing cover and tighten the 15 fastening screws from the inside to tightening torque. Tightening torque of the hexagonhead bolt M6 (8.8) 10 Nm (7.5 ftlb.) 17. Install solenoid hydraulic valve for valve lift adjustment. Put on holder with both hexagonhead bolts M6 x 25 and tighten the screws with tightening torque. Tightening torque of the hexagonhead bolt M6 (8.8) 10 Nm (7.5 ftlb.) 18. Fit the closure cap and the oil extraction pump with new Orings. Tighten the hexagonhead bolts: 3 M6 x 20 for the closure cap and 3 M6 x 35 for the oil extraction pump to tightening torque. Tightening torque of the hexagonhead bolt M6 (8.8) 10 Nm (7.5 ftlb.) 19. Fit four new closure caps (green) for camshaft housing cover in dry state.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing camshafts

486

15 20 37 Disassembling and assembling intermediate shaft

No. Designation 1 Thrust bearing shell half 2 3 Bearing shell half Dumbbell shaft

Qty. Removal 1 1 1

4 5

Snap ring 13 x 1.75

1 1

Check, replace if necessary

Installation Replace, insert in crankcase half of cylinder bank 1 3 Replace, insert in crankcase half of cylinder bank 1 3 Check for true running without any problems; it must be possible to shift shaft slightly Ensure secure seating Ensure secure seating 487

15 20 37 Disassembling and assembling intermediate shaft

einordnung Snap ring 13 x 1.75 Bearing shell half Thrust bearing shell half Snap ring 36 x 1.75 Sprocket wheel Check, replace if necessary 1 1 Replace and insert into crankcase half of cylinder bank 46 Replace and insert into crankcase half of cylinder bank 46 The opening of the snap ring should lie opposite the Woodruff key groove. Warm on heating plate, push on up to stop. Collar points towards intermediate shaft gearwheel

6 7 8 9

Check toothing for wear, press off if necessary

10 Woodruff key 6.0 x 7.5 11 Snap ring 36 x 1.75 12 Sprocket wheel

1 1 1 Check toothing for wear, press off if necessary dispose of The opening of the snap ring should lie opposite the Woodruff key groove. Warm on heating plate, push on up to stop. Collar points towards intermediate shaft gearwheel

13 Woodruff key 14 Thread plug to drive exhaust oil extraction pump M18x1.5 15 Intermediate shaft

1 1

16 Timing gear

Use Torx E10 tool, replace screw, tightening torque 25 Nm (19 ftlb.). Paired with timing gear of the crankshaft, only install together, take note of the identification on the crankcase Check teeth for wear Note reference number, paired with intermediate shaft, only install together

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

15 20 37 Disassembling and assembling intermediate shaft

488

15 55 19 Removing and installing hydraulic valve

Removing the hydraulic valve Installing the hydraulic valve

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Removing the hydraulic valve

Preliminary work: The rear spoiler 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 cleaner and the charge air cooler. To do so, lever out the retaining clip on the top of the charge air cooler and pull the hose out.

3. 15 55 19 Removing and installing hydraulic valve 489

einordnung Pull the lower connecting hose off the charge air cooler. To do so, lever the retaining clip out and pull the hose downwards.

4. Undo the front fastening. Unscrew the fastening nut and the two fastening screws.

5. Undo the bolts on the heat shield. Undo the two sheetmetal nuts on the lower end of the 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 two upper fastening nuts. 9. Remove the cover panel. Unscrew the cover panel located above the plug coils.

10. Remove the adjacent plug coils. Unscrew the two hexagon socket head bolts for this purpose. Pull out the plug coils and hang them to one side.

11. Removing the hydraulic valve 490

einordnung Remove the fastening plate of the switchover valve. To do so, unscrew the two hexagonhead bolts and remove the plate. 12. Remove the switchover valve. To do so, disconnect the electric plug. Press the sheetmetal braces of the plug and pull the plug out at the same time. Then pull the switchover valve out of the cylinder head. WARNING Take care of the coil spring! During removal and installation, make sure that the coil spring is present and does not remain in the camshaft housing.

View of the valve

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Installing the hydraulic valve

1. Replace Oring. Replace the Oring on the hydraulic valve.

Installing the hydraulic valve

491

einordnung

2. Press the hydraulic valve into place. Insert the hydraulic valve into the camshaft housing and press it firmly into place. Place the retaining cover in place. Pay attention to the cutout on the fastening arm. Note In order to make it easier 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 plug coils. Place the adjacent plug coils on the spark plugs again. Tighten the two fastening screws to 10 Nm (7.5 ftlb.). 5. Install heat shield. Tighten the two fastening screws to 10 Nm (7.5 ftlb.).

6. Installing the hydraulic valve 492

einordnung Reinstall the shield of the exhaust system. Tighten the two fastening nuts on the side member for this purpose. 7. Install charge air cooler. To do so, place the charge air cooler back in the vehicle.

8. Tighten the front two fastening nuts and the fastening screw in the wheel well, all to 23 Nm (17 ftlb.). 9. 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 Orings 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 installing rear spoiler. Location Heat shield on camshaft cover Plug coils Fastening screws on the switchover valve Fastening screws on the charge air cooler Fastening nuts on the charge air cooler Thread M6 M6 x 25 M6 x 25 M8 M8 Tightening torque Nm (ftlb.) 10 (7.5) 10 (7.5) 10 (7.5) 23 (17) 23 (17)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing the hydraulic valve

493

15 70 21 Removing cylinder head

Removing cylinder head

15 70 21 Removing cylinder head

494

einordnung

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Designation Fastening nut Washer Cylinderhead gasket Valve keys Upper spring retainer of the exhaust spring Outer valve spring exhaust valve Inner valve spring exhaust valve Valve stem seal Lower valve retainer exhaust valve Spacer exhaust valve Valve guide exhaust valve Exhaust valve seat ring Exhaust valve

Qty. 12 12 1 12 6 6 6 6 6 6 6 6 6

Removal

Installation

Replace, observe marking

Replace

15 70 21 Removing cylinder head

495

einordnung 14 15 16 17 18 19 20 21 22 23 24 25 Valve keys Upper spring retainer inlet valve Outer valve spring inlet valve Inner valve spring inlet valve Valve stem seal inlet valve Lower valve retainer Spacer inlet valve Inlet valve Inlet valve seat ring Valve guide inlet valve Cylinder head Dowel sleeve 6 12 6 6 6 6 6 6 6 6 1 1

Replace

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Removing cylinder head

Preliminary work: Removing 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 internalserration screws in turn steps in the order specified. Work according to the order specified in order to avoid distorting the cylinder head. 3. Remove cylinder head. Lift cylinder head straight upward WARNING Risk of damage! Under no circumstances may carbon deposits on the cylinders be removed by mechanical means

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing cylinder head

496

15 70 23 Installing cylinder head

1. Replace cylinder head gasket. Replace the gasket between the cylinders and the cylinder head. The designation "TOP" must face upwards. 2. Place 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. Handtighten the multipletooth nuts.

3. Tighten cylinder head. The cylinder head screws are tightened in four steps. Important: all four steps must be carried out in the order shown.

15 70 23 Installing cylinder head

497

einordnung Initial tightening to 30 Nm (22 ftlb.). Loosen all screws again in reverse order. Tighten screws to 20 Nm (15.0 ftlb.) Retighten screws to 20 Nm (15.0 ftlb.) Retighten screws with torque angle of 1 x 90.

Location Cylinderhead nuts

Thread

Tightening torque Nm (ftlb.) 30 Nm (22 ftlb.), then loosen; 20 Nm (15.0 ftlb.); then retighten all screws again to 20 Nm (15.0 ftlb.) +90 torque angle

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

15 70 23 Installing cylinder head

498

17 04 19 Removing and installing oil pressure sender

Removal Installation top of page

Removal

1. Undo fastening screw M6x34 on the air cleaner housing. 2. Undo hose clamp between the air cleaner housing and intake 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 clips with a screwdriver. Then return the locking clips to installation position. Additionally undo a fastening screw on the righthand pressure pipe side.

17 04 19 Removing and installing oil pressure sender

499

einordnung

5. Undo pressure pipe middle by removing the spring clip 5 , hose clamp 3 , hexagonhead bolts 1 & 2 and electrical plug 4 .

6. Pull off the electrical plug. Undo the fastening screws and remove the throttle body.

7. Remove 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 the sender. top of page

Installation
1. Fasten sender with new sealing ring. Counter with a second wrench when doing this. Push on the electrical plug. Sender tightening torque: 30 Nm (22 ftlb.) Removal 500

einordnung 2. Install oil temperature sensor with new sealing ring. 3. Check throttle sealing ring and replace it if necessary. Fasten throttle body. Push on the electrical plug. 4. Install pressure pipe. Wet the connecting 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 by tilting and pulling on them. Location Oil pressure sender Thread Tightening torque Nm (ftlb.) 30 (22)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

501

17 07 19 Removing and installing oil temperature sensor

Removal Installation top of page

Removal

1. Undo fastening screw M6x34 on the air cleaner housing (A/f 13). 2. Undo hose clamp between the air cleaner housing and intake manifold. 3. Pull off electrical wire connector of 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 cleaner housing and take out the electrical wire of the hot film mass air flow meter. Reclose the omega clip for the removal (risk of breakage)

4. Tilt the complete air cleaner housing 90 upwards and remove rearwards.

17 07 19 Removing and installing oil temperature sensor

502

einordnung

5. Pull off the connecting hoses between the charge air coolers and the pressure pipe. To do this, unclip the locking clips with a screwdriver. Then return the locking clips to installation position. Additionally undo a fastening screw on the righthand pressure pipe side.

6. Undo pressure pipe middle by removing the spring clip 5 , hose clamp 3 , hexagonhead 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 throttle body.

8. Pull off plug, unscrew oil temperature sensor by using a straight ring wrench, A/f 22. top of page

Installation
1. Fasten oil temperature sensor with new sealing ring. 2. Check throttle sealing ring and replace it if necessary. Fasten throttle body. Push on electrical plug. Removal 503

einordnung 3. Install pressure pipe. Wet the connecting 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 by tilting and pulling on them. 4. Install air cleaner assembly 24 25 19 install and remove air cleaner . Location Oil temperature sensor Thread Tightening torque Nm (ftlbs.) 30 (22)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

504

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

einordnung

No. 1 2 3 4 5 6 7 8 9

Designation Oil drain plug Copper sealing ring 20 x 24 Hexagonhead bolt M8 x 35 Hexagon nut with washer M8 Hexagonhead bolt M6 x 16 Hexagonhead bolt M8 x 30 Check valve

Qty. 1 1 1 1 2 1 1

Removal Hold

Installation Hold; tightening torque 60 Nm (44 ftlb.) Replace

Tightening torque 10 Nm (7.5 ftlb.)

Sealing ring 21.89 x 2.62 2 Sealing ring 30 x 2.5 1

Check for smoothness of operation; it must not stick in any position. Replace if necessary. Replace; coat with Vaseline Replace; coat with Vaseline

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Removal
1. Raise the vehicle at the jacking points. CAUTION Danger of material damage if the vehicle is raised incorrectly or if the vehicle is driven incorrectly onto the lifting platform! Lift the vehicle only at the takeup points shown in the figure! When driving onto a platform lift, make sure that there is sufficient distance between the platform lift and the vehicle! Removal 506

einordnung 2. Remove oll filler cap.

3. Undo the oil drain plug (a/f 19) on the oil container. Make sure to counter with a wrench (a/f 27) when doing this. Unscrew the loosened plug and drain the oil. CAUTION Danger of scalding from draining oil! Take suitable protective measures to avoid scalding 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. Unscrew the oil drain plug (a/f 15) and drain the oil. Then equip the plug with a new sealing ring and tighten. Tightening torque 70 Nm (52 ftlb.). CAUTION Danger of scalding from draining oil! Take suitable protective measures to avoid scalding by hot oil

Removal

507

einordnung

6. Undo the lower righthand fastening point of the oil tank.

7. Loosen and remove two hexagonhead bolts (M6 x 16) on the flexible flange of the oil tank. 8. Carefully press the flexible flange off the check valve with a plastic spatula; a second person should press the oil tank to the right at the same time. Insert a suitable piece of wood between the crankcase and oil 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

Installation
1. Coat the new sealing rings of the check valve with Vaseline and fit them. Push the oil container aside at the same time. 2. Equip the flexible flange with a new sealing ring, put the flange on the check valve without using excessive force and fasten it in place.

3. Screw down the oil tank fastening point on the lower right side. Installation 508

einordnung 4. Fill in engine oil. Note The oil change quantity (without oil filter change) is approx. 7.8 litres after a dripping time of 20 minutes! 5. Warm the engine up to operating temperature and carry out a leak test. 6. Check the 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 onboard computer display lights up. The following conditions must be maintained for the measurement. Vehicle horizontal Engine at operating temperature Engine idling Vehicle stationary

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

509

17 40 19 Removing and installing oil cooler removed

Removing oil cooler Installing oil cooler The following prelimiminary work must be carried out: Remove and install oil container => Removing and installing oil container. Remove intake distributor 244619 Removing and installing intake distributor .

Engine

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Removing oil cooler

1. Remove crankcase ventilation tube. Unscrew the two M6 screws arrows for this purpose.

2. Undo the union nut arrow and remove the crankcase ventilation tube.

3. Undo the holder behind the oil cooler. Unscrew the M6 screw arrow for this purpose.

17 40 19 Removing and installing oil cooler

Engine removed

510

einordnung

4. Pull coolant hose 2 off the oil cooler 1 . To do so, unscrew the screwtype hose clamp from the coolant hose 2 and pull off the coolant hose.

5. Unscrew the four M6 screws arrows on the oil cooler and remove the oil cooler. 6. Suck out remaining oil. top of page

Installing oil cooler

Note Always replace the Orings for the oil cooler!

1. Replace seals. Replace the four Orings arrows between the bracket and oil cooler. Coat the Orings with a small amount of universal grease and insert. 2. Place oil cooler in position with the four M6 screws and tighten. Tightening torque of M6 screws = 10 Nm (7.5 ftlb.)

Removing oil cooler

511

einordnung

3. Fasten coolant hose 2 on the oil cooler 1 . To do so, place the coolant hose 2 in position and tighten the screwtype hose clamp.

4. Install the crankcase ventilation tube. For this purpose, place the crankcase ventilation tube with the union nut 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. Tightening torque for hexagonhead bolts 10 Nm (7.5 ftlb.)

6. Tighten the union nut on the crankcase ventilation tube arrow with the correct tightening torque. Tightening torque for union nut 30 Nm (22 ftlb.) Installing oil cooler 512

einordnung 7. Install intake distributor 244619 Removing and installing intake 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, 996650, 996651, 996840, 996841

Installing oil cooler

513

17 52 19 Removing and installing oil container

Removing oil container removal overview Installing oil container Preliminary work: 100119 Removing and installing engine

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Removing oil container removal overview

17 52 19 Removing and installing oil container

514

einordnung

1. Detaching oil return line and 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.

Removing oil container removal overview

515

einordnung 2. Pulling plug off oil level sender and detaching oil line c. Pull plug off the oil level sender and set it aside. d. Detach the return line from the cylinder head. Make sure to counter with a wrench when doing this in order to prevent damage to the oil container.

3. Detaching positive crankcase 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. Detaching inlet line Detach inlet line between the oil container and the engine. Unscrew the two hexagon socket head bolts for this purpose.

5. Undo fastening screws Undo the two oil container fastening screws at the sides. top of page

Removing oil container removal overview

516

einordnung

Installing oil container

1. Tightening fastening screws Tighten the two oil container fastening screws at the side holders. Tightening torque: 23 Nm (17 ftlb.)

Installing oil container

517

einordnung

2. Tightening inlet line a. Fit a new Oring on the inlet line between the oil container and engine and insert the line. b. Tighten the two hexagon socket head bolts. Tightening torque: 9.7 Nm (7 ftlb.)

3. Tightening positive crankcase ventilation and oil container fastening 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 level sender plug and tightening the oil line e. Push on the oil level sender connecting cable again. f. Tighten the oil return line of the cylinder head. Make sure to counter with a wrench at the oil container when doing this.

Installing oil container

518

einordnung

5. Tightening oil return line and vent line g. Tighten oil return 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, 996650, 996651, 996840, 996841

Installing oil container

519

19 38 17 Draining and filling in coolant

Caution Draining coolant Filling in coolant Bleeding the cooling system CAUTION Risk of damage! The drain cocks of the front radiator and side radiators 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 cocks.

1. Close drain cocks manually .

2. Check position of the locking springs on the drain cocks. The bows of the locking springs must always point up.

19 38 17 Draining and filling in coolant

520

einordnung CAUTION Severe damage can occur if the installation position is incorrect (twisted out of position). 3. Vent the cooling system in connection with the System Tester 2 . Use menu item "Special functions" for this purpose. top of page

Draining coolant
1. Unscrew cap on coolant expansion tank.

2. Undo coolant drain plugs on right and left and drain the coolant. Equip drain plugs with new seals. Tightening torque 10 Nm (7.5 ftlb.) to 15 Nm (11.0 ftlb.). top of page

Filling in coolant
Note The engine cooling system is factoryfilled with a lifetime engine coolant. This engine coolant must not be mixed or replaced with other coolants. Use only original Porsche coolant when changing or topping up the engine coolant.

top of page

Bleeding the cooling system

Note The cooling system is bled in connection with the Porsche System Tester 2 1. Connect the Porsche System Tester 2 and switch on the ignition. 2. Select menu item "Special function" in the "Vehicle type" menu. 3. Press the key to change to the "Control units" menu. 4. Select menu item "Cooling system" in the "Control units" menu and press the >> key. Note

Draining coolant

521

einordnung The following message appears on 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

Bleeding the cooling system

522

19 40 19 Removing and installing coolant expansion tank

Removal Installation

top of page

Removal

1. Unscrew the fastening 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 mass air flow meter. Open omega clip. Remove electrical wire.

19 40 19 Removing and installing coolant expansion tank

523

einordnung

3. Tilt the air cleaner housing upwards to the right by 90 and then turn the air cleaner housing and remove from the engine compartment.

4. Unscrew the hose clamp (a/f 7) between the air cleaner housing and the cowl. Note In order to avoid any damage when removing the intake pipes, pull off the connector. 5. Pull off the electrical connector on the solenoid hydraulic valve of the cylinder bank 13. 6. Undo pressure pipe middle by removing the spring clip 5 , hose clamp 3 , hexagonhead bolts 1 & 2 and electrical plug 4 . 7. Pull off vacuum hose to the control valve.

8. Unscrew fuel return line 1 and fuel supply line 2 . It is important to counter when performing this step. 9. Remove fuel filter.

Removal

524

einordnung

10. Completely remove fuel filter with holder. To to this, bend the retaining clip upward as shown arrow and at the same time remove the filter with holder.

11. Remove holder for fuel return line on the intake pipe (hexagonhead bolt M 6).

12. Undo three fastening screws on the front intake distributor separation point.

13. Remove hose clamp and pull off ventilation hose from the intake pipe.

14. Removal 525

einordnung Unscrew upper hexagonhead bolt, lift intake pipe out of the shaft bolt and remove rearwards. Remove and dispose of seal. 15. Disconnect coolant hose with commercially available hose clip.

16. Unscrew spring band clamp or hose clamp on the 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 container.

19. Disconnect electrical plug connection from the sensor for the coolantlevel indicator.

20. Undo the hexagon nut.

21. Pull coolant expansion tank out of the guide rails and remove rearwards. top of page

Removal

526

einordnung

Installation

1. Push coolant expansion tank into the guide rails and fasten. 2. Attach connector from the sensor for the coolantlevel indicator.

3. Fasten the coolant hose with a new hose clamp 999.512.552.00 . Observe the installation position of the screwtype 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 the shaft bolts, at the same time push the hose of the recirculating air valves onto the suction line. Fasten the hexagonhead bolt.

Fasten ventilation line from the oil tank onto the intake distributor.

Installation

527

einordnung

Fasten separation point. 5. Position the fuel filter with holder on the coolant expansion tank and press it down at the 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. Perform tightness test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

528

19 50 19 Removing and installing coolant pump (engine installed)

Tools Removal Installation 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 page

Removal
1. Raise the vehicle at the prescribed jacking points. 2. Open engine compartment lid. 3. Disconnect battery. 4. Remove rear spoiler 635519 Removing and installing rear spoiler . 5. Remove bumper with shield.

19 50 19 Removing and installing coolant pump (engine installed)

529

einordnung

6. Remove lateral shields.

7. Loosen fastening nuts.

8. Loosen fastening nuts on the turbocharger. Remove the shield.

9. Detach restraining straps. Undo the two restraining straps on the rear muffler. Loosen the two hexagon socket screws for this 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. Push restraining straps out of the holder. Push the restraining strap into the recesses of the engine carrier with a screwdriver and move outward. 11. Remove rear mufflers. Two persons can now remove the rear muffler.

Removal

530

einordnung

12. Undo fastening screw M 6 x 34 on the air cleaner housing. 13. Undo hose clamp between the air cleaner housing and intake manifold.

14. Tilt the complete air cleaner housing 90 upward and then remove from the engine compartment.

15. Pull off the connecting hoses between the charge air 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 pressure pipe: Disconnect connector on the temperature pressure sensor arrow 4 . In order to do this, undo 2 spring band clamps and 1 screwtype hose clamp A/f 7 (arrow 5 and arrow 3 , 1 hose clamp not illustrated) and 3 hexagonhead bolts A/f 10 (arrow 1 and arrow Removal 531

einordnung 2 ). Pull off vacuum hose to the control valve.

17. Disconnect oxygen sensor plug on the rear closing panel.

18. Disconnect oxygen sensor plug. 19. Undo the three fastening screws of the belt pulley on the hydraulic system pump by approx. 1/2 turn.

20. Relieve drive belt. 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 expansion tank. Undo coolant drain plugs on left and right and collect coolant in a suitable container, so that it can be reused. 22. Equip drain plugs with new sealing rings and then fasten. Tightening torque: 10 to 15 Nm (7.5 to 11 ftlb.). Note Removal 532

einordnung When swiveling, make sure not to damage the bellows on the lower joint!

23. Undo stabilizer of the cross member and swivel downwards or disengage.

24. Support the enginetransmission unit: In order to do this, fasten special tool (retaining device) 9624/1 on the takeup points of the stabilizer mounts. 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 from the coolant guide housing. WARNING Damage to the console and the oil lines can occur. After the engine carrier has been separated the bracket is only held by the oil lines and the Orings. The auxiliary screws can only be removed once the coolant pump has been fastened.

Removal

533

einordnung

27. Immediately secure the bracket with a shorter auxiliary screw (M10 x 55).

28. Loosen and remove belt guard on the coolant pump. 29. Loosen hose clamp and pull 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 onto the coolant pump. Tightening torque: 10 Nm (7.5 ftlb.).

3. Install belt guard. 4. Fasten coolant filler hose onto the coolant pump.

Installation

534

einordnung

5. Remove auxiliary screw again.

6. Fasten engine carrier onto the bracket. Tightening torque: 65 Nm (48 ftlb.). 7. Fasten engine carrier onto the engine mounts (a/f 18). Tightening torque: 85 Nm (63 ftlb.).

8. Remove special tool (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. Move the rear muffler into installation position and push the two tensioning straps over the holder on the engine carrier. Subsequently tighten the two hexagon socket head bolts slightly.

Installation

535

einordnung

11. Push the heat shields over the studs of the exhaust turbocharger. Fit new hexagon nuts. Tightening torque: 30 Nm (22 ftlb.). 12. Tighten restraining straps on the rear muffler. Tightening torque: 15 Nm (11 ftlb.). 13. Fit heat shields, bumper and rear spoiler.

14. Install drive belt 13 78 19 removing and installing drive belt . 15. Check that the installation 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 control valve. Fix connector onto the temperature pressure sensor. Fasten pressure pipe with 2 spring band clamps, 1 screwtype hose clamp and 3 hexagonhead bolts (a/f 10, 10 Nm (7.5 ftlb.)). 17. Attach new O rings onto both pressure hoses and coat the Orings and takeup bores on the pressure pipe with plenty of water.

Installation

536

einordnung

18. Push the right and left pressure hoses into the pressure pipe, until they audibly engage. 19. Make sure that the pressure hoses have been fitted correctly, by tipping and pulling on the pressure hoses.

20. Install air cleaner housing. 21. Fasten hot film mass air flow meter line: Open omega clip on the lefthand 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 cooling system is bled in connection with the Porsche System Tester 2. Select special functions. Menu point. 24. Bleed the cooling system => Draining and filling in coolant.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

537

19 62 19 Removing and installing coolant hose at front left (Ytype coolant distributor)
Tools Removal Installation top of page

Tools

Item Designation Springband clamp pliers

Special tool Commercially available; refer to Workshop Equipment Manual, Chapter 2.4, No. 72 or 73

Explanation For opening and closing springband clamps

top of page

Removal
1. Unscrew wheel bolts of the front left wheel. 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 left wheel housing liner 50 56 19 Removing and installing front wheel housing liner.

6. Undo and remove the left diagonal brace between the body and the side member. To do this, unscrew the two fastening screws M 12 x 25 (arrow) . Note Pull off the complete flange on the radiator. Do not loosen the hose clamp.

19 62 19 Removing and installing coolant hose at front left (Ytype coolant distributor)

538

einordnung

7. Drain coolant. To do this, unclip the locking spring on the flange for the coolant hose and pull the coolant hose off. Approx. 5 litres of coolant will pour out. Collect the coolant.

8. Pull the pipe holder off the support after first lifting the holding straps somewhat with a small screwdriver. Then pull the coolant line with the holder off the support. 9. Push the right hose clamp down. Loosen the hose clamp at the connection between the coolant pipe of the left radiator and the Ytype distributor, then remove the complete coolant line between the radiator and the Ytype 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 pipe (to the middle radiator) and at the Ytype distributor. In order to facilitate work when pulling off the hose connection, cut the hose open vertically with respect to its end face over a length of approx. 4 cm. The coolant pipe must not be damaged during this procedure.

11. Loosen the lower hose clamp. Loosen the hose clamp at the connection point between the Ypipe and the coolant pipe. 12. Pull off the Ytype coolant distributor. To do this, pull the Ytype distributor off its three connection points and take it out of the installation area.

Removal

539

einordnung top of page

Installation
1. Put the two hose clamps back onto the connections which lead to the radiators. Fit the hose clamp above the lower flange. Note In order to facilitate fitting, wet the inside of the coolant hose with water in the fitting area and push the hose onto the coolant pipes. 2. Return the Ytype distributor to installation position and push on the three connections. 3. Refit the rear hose clamp on the connection point of the Ytype distributor and on the coolant pipe of the middle radiator. 4. Reposition the hose clamp between the Ytype distributor and the left radiator. Tighten the hose clamp.

5. Reposition the lower hose clamp on the Ytype distributor and tighten it.

6. Push the locking clip back onto the radiator flanges. Make sure that the locking clip has been properly inserted when doing this.

7. Position the coolant line in relation to the left radiator and clip the holder in again. 8. Replace the Oring on the coolant hose flange.

Installation

540

einordnung

9. Wet the Oring with plenty of water in order to facilitate fitting the coolant hose. Push on the coolant hose. Press the coolant hose firmly onto the connection neck. The locking clip of the hose fitting must audibly engage. Then recheck the correct fitting by tilting and pulling on the coolant hose. WARNING Coolant hose can pop off Check whether the coolant hose fitting is securely seated. Never treat hose connections 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 guides.

11. After fitting the Ytype coolant distributor, additionally check the position of the locking springs and whether the coolant drain cocks are correctly engaged. The bows of the locking springs must always point up. 12. In order to check proper engagement, manually turn the flange of the drain cocks counterclockwise and clockwise. There must be approx. 1 mm play in both directions.

Installation

541

einordnung

Turn drain cock counterclockwise

Turn drain cock clockwise 13. Fit and fasten the left diagonal brace. Tightening torque 100 Nm (74 ftlb.). 14. Fit front part of the wheel housing liner and the underbody cover 50 56 19 Removing and installing front wheel housing liner. 15. Mount front wheel. 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 function , => Draining and filling in coolant. 17. Then check the cooling system for leaks. Location Left diagonal brace Front wheel Thread M12 x 25 x 1.5 Tightening torque Nm (ftlb.) 100 (74) 130 (96)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

542

20 02 01 Checking fuel pressure

Caution WARNING Observe the general safety instructions when working on the fuel system and when handling petrol and other fuels => Precautionary measures when working on fuel system ! Attach or mount a warning notice on the vehicle 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 A

Designation Connecting lead 9559 Pressure gauge P 378a

Source see workshop equipment manual chapter 2.2.2 see workshop equipment manual chapter 2.2.1

Remarks In connection with pressure gauge for connecting to the flange of the fuel pressure line

Note 20 02 01 Checking fuel pressure 543

einordnung The battery voltage may not fall below 12 volts during the fuel pressure check! 1. Check the charge state of the battery, e.g. using a voltmeter or the Porsche System Tester PST 2. The battery voltage must not fall below 12 volts during the check. Note Use the brass closure cap on the test connection of the fuel pressure line only once as the sealing ring cannot be replaced. To avoid possible leaks, the cap must be replaced after removal! 2. Release the metal cap on the test connection of the pressure pipe from the fuel filter to the fuel collection pipe and screw it off by hand (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 engine is standing still: 4. Connect the Porsche Tester PST 2 in the vehicle, switch on the ignition and switch off all loads, such as the radio and air conditioning.

5. Activate fuel pump relay using Porsche System Tester. To do this, select the line drive links in the DME control unit individual search and then select fuel pump relay see figure . Activate by pressing the F8 key.

6. Read value on pressure gauge. Target test values when engine not running: 3.8 0.2 bar. 7. Switch off the fuel pump relay on the System Tester by pressing F8 . 20 02 01 Checking fuel pressure 544

einordnung 8. Switch off ignition, pull off System Tester connecting lead in the vehicle and switch off System Tester. Checking while engine is idling: 9. To check the engine while it is idling, connect the pressure gauge as described above and start the engine. Switch off the engine after reading the fuel pressure. 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 tool. Collect emerging fuel, e.g. with a cloth. 11. Position new closure cap on test connection and tighten (a/f 13 mm). Tightening torque of new brass closure cap: 2.5 0.5 Nm ( 0.5 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

20 02 01 Checking fuel pressure

545

20 10 19 Removing and installing fuel tank

Caution Removing fuel tank Installing fuel tank WARNING Observe the general safety instructions when working on the fuel system and when handling petrol and other fuels => Precautionary measures when working on fuel system ! Attach 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 scalding when the engine is hot. Do not begin working until the engine has cooled down! When handling coolant, wear protective gloves and goggles! In case of contact with the skin or eyes, wash immediately with plenty of water!

20 10 19 Removing and installing fuel tank

546

einordnung

No. Designation 1 Union nut 2 3 4 5 6 7 8

Fuel level sensor Sealing ring Tank closure Hexagonhead bolt M6 x 12 Fuel evaporative valve 1 Vent hose 1 Filler neck 1 1 1

Qty. Removal 1 VW / Audi socket wrench 3217 1 1 1 2

Installation Replace and secure with a spot of hotmelt adhesive; tightening torque 70 Nm (52 ftlb.) Replace Grease sealing ring with Vaseline Tightening torque 10 Nm (7.5 ftlb.)

Protect wing from damage

Apply a thin coat of silicone spray in the fitting area Replace 547

9 Supporting ring 10 Seal

20 10 19 Removing and installing fuel tank

einordnung 11 Combination screw M8 x 40 12 Restraining strap (right and left) 13 Combination screw M8 x 40 14 Restraining strap (transverse) 15 Bottom guard 16 Fuel tank 2 2 2 1 1 1 Tightening torque: 23 Nm (17 ftlb.) Loosen before Engage in front subframe removal of frontaxle Tightening torque: 23 Nm (17 ftlb.)

Do not pinch fuel level sensor

top of page

Removing fuel tank

Note To lock the steering wheel, use only the steering wheel holder A approved for airbags to prevent damage or injury should an airbag be released!

1. Move steering wheel to centre position (front wheels straightahead) and lock it with the steering wheel holder arrow . Note Before disconnecting the battery, observe the work instructions 9 Work instructions after disconnecting the battery ! 2. Disconnect battery. Disconnect negative terminal and cover the terminal or battery. 3. Remove the front wheels, using the prescribed special tool socket wrench insert P 300 to avoid damage to the wheels. 4. Remove front wheel housing liner 50 56 19 Removing and installing front wheel housing liner . Note It is impermissible to suck out the fuel through the filler neck, as this can damage the inner flap on the filler neck. Always suck out the fuel through the hole for the fuel level sensor.

Removing fuel tank

548

einordnung Remove fuel level sensor. 5. Empty the fuel tank. The fuel must be sucked out through the hole for the fuel level sensor. To do this, remove the closure cap in the luggage compartment (unscrew four hexagon nuts a/f 10) and disconnect all cable plugs and fuel lines from the fuel level sensor. Undo union nut with special tool socket wrench 3217 , carefully remove the fuel level sensor and place in a clean container, e.g. a bucket. Remove the fuel using a suitable fuel extractor. Cover hole for the fuel level sensor with a cloth or similar. Note To remove and install the front wheel drive the help of a second person is necessary 6. Remove the frontwheel drive complete with cardan shaft. Get a second person to help. See also 39 88 19 Removing and installing front wheel drive 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 coolant pipe) with hose clamps. Drain coolant at the radiator drain plug 19 38 17 Draining and filling in coolant . Collect coolant in a clean container for reuse.

8. Retighten drain plugs. Undo the coolant pipes and vent line at the cardan tunnel. To do so, slide off the springband clamps at the rear using springband clamp pliers, unclip from the plastic holders, and unscrew the two hexagonhead bolts M6 Item 1 and the two hexagon nuts M6 Item 3 at the front pipe holder. Place a coolant collecting container ready, secure the pipes with wire and then pull from the rear coolant hoses. Collect the draining coolant and allow pipes to drain.

9. Detach tank filler neck. To do so, remove closure cap and unscrew the hexagon bolt M6 x 12 arrow .

Removing fuel tank

549

einordnung

10. Unclip seal of the filler neck in the right front wheel well 1 . Disconnect plug connections for the vent lines at the filler neck 2 . Press release buttons and simultaneously pull the lines apart. Disconnect ground strap 4 on the plug. Disconnect vent line to fuel tank 3 behind the spring strut. Note To avoid damage to the wing when removing and installing the filler neck, suitable protective covers must be placed. 11. Turn the filler neck clockwise by approx. 45 and pull 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) arrow at steering gear. Take out the fit bolt M8 x 35 and slide the universal joint upwards. If necessary, carefully force apart the clamping piece with a screwdriver and spray with rust solvent. Replace fit bolt. Note The suspension subframe must be lowered. To do this, undo the two screws fastening the steering gear to the suspension subframe.

13. Detach steering gear from the suspension subframe. To do this, unscrew the two hexagonhead bolts Removing fuel tank 550

einordnung M10 x 1.5 a/f 15 (on the underside of the suspension subframe) 5 and press off the steering gear 48 90 19 Removing and installing steering gear .

14. Support suspension subframe with a transmission jack. Pull off the cable plug on the sensor of the headlight beam adjustment right arrow . Detach stabilizer from the mount. To do this, remove the hexagon nut M10 from each joint left arrow in the Figure , countering with an openended wrench at the joint hexagon.

15. Detach suspension subframe. Undo the six hexagonhead 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 springband clamps Item 4, upper part of Figure on the coolant hoses at the front and pull off the coolant pipes.

17. Undo a springband clamp for the vent line on the distributor hose in the left front wheel well 1 . Remove coolant pipe.

18. Pull off vent line from distributor hose in the left front wheel well Item 2, previous Figure and unclip from the two holders under the fuel tank arrow . Remove line on the coolant hose in the right front

Removing fuel tank

551

einordnung wheel well by undoing the springband clamps. If necessary, collect the draining coolant. Pull off vent line to the side. Note Observe the installation position of both connector tubes to the radiators in relation to the plastic holders. 19. Disconnect both connector tubes to the radiators under the fuel tank and remove. To do this, undo hose clamps on the coolant hoses.

20. Remove both plastic holders complete with coolant pipes 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 holders in the wheel wells. Observe installation position of the coolant pipes!

21. Detach fuel tank restraining strap (transverse) from the body by unscrewing the two hexagonhead bolts M8 x 40 arrow .

22. Lift the fuel tank from the support lugs arrows and, with the help of a second person, carefully remove in a downward direction (avoiding damage to the hole for the fuel level sensor). top of page

Removing fuel tank

552

einordnung

Installing fuel tank

Note Fix connecting cable and fuel lines, using adhesive tape if necessary, to the body aperture for the fuel level sensor Observe line routing between fuel tank and body (e.g. chafing, pinching)

1. Lift the fuel tank with the help of a second person and carefully insert from below (avoiding damage to the hole for the fuel level sensor). Engage fuel tank on the support lugs on the floor of the body arrows .

2. Install fuel tank restraining strap (transverse). Position hexagon bolts M8 x 40 at the sides of the body and tighten arrow . Tightening 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 hotmelt adhesive. Fit closure cap in the luggage compartment (screw tight the four hexagon nuts a/f 10) 20 66 19 911 Carrera 4 (996) Removing and installing fuel pump . Tightening torque for union nut 70 Nm (52 ftlb.) 4. Preposition connector tubes to the radiators together with premounted holders (replace if necessary) in installation position under the fuel tank. Clip holders to the body. To do this, hook the holders at the front and engage the tab at the rear. Push the left and right pipes into coolant hoses and tighten screwtype hose clamps.

Installing fuel tank

553

einordnung

5. Insert vent line into distributor hose in the left front wheel well 2 and into coolant hose in the right front wheel well and fit the springband clamps.

6. Clip vent line into the two holdersarrows on the coolant pipes.

7. Fasten coolant pipes at front. To do this, insert two aluminium pipes and a vent line in the network into the corresponding coolant hoses and fit the five springband clamps (1 clamp for 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 hexagonhead bolts and two M6 hexagon nuts Items 1 and 3 in next Figure and fix coolant pipes on the vehicle underbody in the holders. Push coolant pipes into the coolant hoses to the engine, tighten the springband clamps and remove the hose clamps again. Tightening torque of the hexagonhead bolts M6: 10 Nm (7.5 ftlb.) Note When lifting the suspension subframe, protect servo lines of the steering from damage

Installing fuel tank

554

einordnung

9. Carefully lift suspension subframe and fix with the six hexagonhead bolts Items 2, 6 and 7 . Screw suspension subframe into place to the prescribed tightening torque. Tightening torque M14 x 1.5 : 160 Nm (118 ftlb.) (Item 2 ) Tightening torque of corner plate to side member M10 x 1.5 : 65 Nm (48 ftlb.) (Item 6 ) Tightening torque of corner plate to body M12 x 1.5 : 100 Nm (74 ftlb.) (Item 7 )

10. Fit stabilizer to mount left arrow . To do this, screw two M10 hexagon nuts on the joint heads, simultaneously countering at the joint hexagon with an openended 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 hexagonhead bolts for fastening the steering gear to the suspension subframe and the fit bolt for the universal joint whenever they have been removed. Screw threads must be clean and free of grease.

11. Position the steering gear with the centring sleeves in the throughholes on the suspension subframe and screw into place with two new hexagonhead bolts a/f 15 M10 x 1.5 to the underside of the suspension frame 5 48 90 19 Removing and installing steering gear . Tightening torque 65 Nm (48 ftlb.).

Installing fuel tank

555

einordnung

Note

The lug on the toothed steering gear pin must engage in the clamping slot of the universal joint arrows .

12. Push universal joint of the steering shaft onto the toothed steering gear pin. The lug must engage in the clamping slot of the universal joint. Insert new fit bolt M8 x 35 into the retaining groove arrow and tighten with the prescribed torque. Tightening torque: 23 Nm (17 ftlb.) 13. Install the front 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 area. 14. Fit filler neck. Remove protective cap on fuel tank. Carefully push the filler neck with rotary movements into the flange on the fuel tank (protect wing and wheel well from damage). Fit vent lines and ground cable Items 2, 3 and 4 in the next figure by connecting to the filler neck.

15. Fit seal in correct position 1 . Ensure that the locking tabs are seated correctly.

Installing fuel tank

556

einordnung

16. Tighten hexagonhead bolt M6 x 12 of the filler neck arrow . Coat seat of the cap seal with Vaseline. Tightening torque 10 Nm (7.5 ftlb.) 17. Fill and bleed cooling system 19 38 17 Filling and bleeding the cooling system . 18. Refill fuel tank. 19. Calibrate fuel level sensor system => Calibrating fuel level sensor system. 20. Install front wheel housing liners 50 56 19 Removing and installing front wheel housing liner . Note Observe specification for greasing wheel bolts 44 05 19 Removing and installing wheel . 21. Fit the front wheels, using the prescribed special tool socket wrench insert P 300 to avoid damage to the wheels. Tightening torque of the wheel bolts : 130 Nm (96 ftlb.). 22. Connect the battery 9 Work 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, tires, suspension alignment .

Tightening torques for front axle and fuel tank

Location Cross member/side member on body (front and rear) Corner plate on body Diagonal brace on body and side member Frontaxle drive shaft to final drive Rear frontaxle transmission support to body Front frontaxle transmission support to frontaxle cross member Stud to frontaxle cross member Tank strap to body Stabilizer mount to stabilizer Universal joint (steering shaft) to steering gear Steering gear to cross member Tightening torques for front axle and fuel tank

Thread M14 x 1.5 M12 x 1.5 M12 x 1.5 M8 M10 M10 M8 M8 M10 M8 M10 x 1.5

Tightening torque Nm (ftlb.) 160 100 100 39 65 65 20 23 46 23 65 557

einordnung Wheel to wheel hub M14 x 1.5 130

996410, 996411, 996420, 996421, 996450, 996451, 996430, 996431, 996610, 996611

Tightening torques for front axle and fuel tank

558

20 15 01 Calibrating fuel level sensor system

Caution WARNING Danger of fire and injury! Observe general safety regulations on the fuel system! Wear protective gloves! Note Calibration is necessary after replacement of the fuel tank, fuel level sensor or instrument cluster. The fuel level sensor system need not be calibrated if the battery was disconnected or a plug connection on the instrument cluster or fuel level sensor was removed. The values remain stored in the instrument cluster. A range on remaining fuel of less than 15 km is not displayed in the instrument cluster. 1. Disconnect the battery and cover terminal or battery. 2. Remove cap over the 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. Fuel extractor: Refer to the Workshop Equipment Manual, Chapter 3 "Workshop Equipment". 5. Make sure that the two recesses on the left and righthand sides of the tank are emptied completely. 6. Reinstall the fuel level sensor and, with "ignition off", fill the tank with 28 litres of fuel. 7. Perform tank calibration with the Porsche System Tester 2: Select vehicle type (911 Carrera) Select control modules Select instrument cluster Select menu item "Tank calibration" Confirm calibration 8. The fuel level sensor system has now been calibrated.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

20 15 01 Calibrating fuel level sensor system

559

20 39 19 Removing and installing fuel return line

Removal Installation top of page

Removal
1. Remove enginetransmission unit 10, 10 removing and installing engine 2. Remove coolant expansion tank.

Undo the hexagon nut.

Disconnect electrical plug connection from the sensor for coolantlevel indicator.

Pull coolant expansion tank out of the guide rails and remove.

20 39 19 Removing and installing fuel return line

560

einordnung

3. Open line holder.

4. Disconnect line plug connection on the vehicle floor. In order to do this, press button and at the same pull the wires apart. Collect residual fuel. 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 the lines onto the plug connections. The plug must engage audibly. Correct engagement of the plug connection must be checked with a gentle pull.

Removal

561

einordnung

3. Close line holders. 4. Push coolant expansion tank into the guide rails and fasten.

5. Attach connector from the sensor for the coolantlevel indicator. 6. Install engine again 10 removing and installing engine.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

562

20 60 55 Replacing fuel filter

Removing fuel filter

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 the same time.

20 60 55 Replacing fuel filter

563

einordnung

2. Pull off the connecting hose between the left turbocharger and the intake pipe. To do this, unclip the retaining clip using a screwdriver and pull out the hose. Refit 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 pipe.

5. Tilt air cleaner housing outwards. To do this, tilt the housing upwards on the right by 90 and then turn the housing 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 of the engine compartment.

Removing fuel filter

564

einordnung

7. Pull off the ground cable from the fuel filter.

8. Undo fuel pressure line. Make sure to counter with a wrench when doing this. Collect emerging fuel.

9. Disconnect 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 the filter with holder. 11. Remove fuel filter. To do this, fully open the restraining strap and take the fuel filter out.

Removing fuel filter

565

einordnung

12. Push the new fuel filter into the restraining strap and tighten again. Position the filter in such a way that the mark arrows on the filter is aligned with the outer edge of the holder in installation position. 13. Position 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. Pull slightly to ensure that the connection is properly locked.

15. Tighten fuel pressure line. Make sure to counter with a wrench when doing this.

16. Connect the ground cable to the filter. 17. Removing fuel filter 566

einordnung Clip in hot film mass 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.

18. Place the air cleaner housing in the engine compartment as shown and move into installation position. To do this, first turn the housing to the 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. Reconnect the plug on the hot film mass air flow sensor. The plug must engage audibly!

21. Attach the connecting hose between the left turbocharger and the intake distributor. The hose must engage audibly!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing fuel filter

567

20 66 01 Checking quantity delivered by fuel pump

Caution WARNING Observe the general safety instructions when working on the fuel system and when handling petrol and other fuels => Precautionary measures when working on fuel system ! Attach or mount a warning notice on the vehicle in a clearly visible position 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 A B

Designation Connection hose 9507 Receptacle

Source see workshop equipment manual chapter 2.2.2 Original Porsche spare parts; part number 996.106.255.00

Remarks Insert receptacle in open end of the hose To connect to the rapidaction coupling of the fuel return line

Note 20 66 01 Checking quantity delivered by fuel pump 568

einordnung The battery voltage may not fall below 12 volts during the fuel pressure check! 1. Check the charge state of the battery, e.g. using a voltmeter or the Porsche System Tester PST 2. The battery voltage must not fall below 12 volts during the check. 2. Connect the Porsche Tester PST 2 in the vehicle, switch on the ignition and switch off all loads, such as the radio and air conditioning. 3. Remove the rear and middle underside panels. To remove the rear panel, the left side panel must also be loosened, see 911 Carrera (996), 51 90 19 Removing and installing underside panels , position 4, 5 and 9.

4. Loosen the rapidaction coupling on the fuel return line arrow ; to do this, press in the locking lug and pull off the coupling. 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 rapidaction coupling of the fuel return line. Be sure that the coupling is fitted correctly (must engage audibly) by pulling the line apart! 6. Put the open end of the hose in a petrolresistant canister. Keep a stopwatch at hand for the following measurement.

7. Activate the fuel pump relay using the Porsche System Tester PST 2. To do this, select the line drive links in the DME control unit individual search and then select fuel pump relay. Activate by pressing F8 see figure . After 30 seconds, deactivate the relay again by pressing F8 . 8. Transfer the collected fuel into a suitable measuring cup. Target value for supplied fuel quantity: in 30 seconds, at least 1.25 litres 9. 20 66 01 Checking quantity delivered by fuel pump 569

einordnung Remove the receptacle with hose and insert the rapidaction coupling onto the fuel return line. Be sure that the coupling is fitted correctly (must 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 disconnect.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

20 66 01 Checking quantity delivered by fuel pump

570

20 68 19 Removing and installing fuel cooler

Removing fuel cooler Installing fuel cooler top of page

Removing fuel cooler

Note It is necessary to remove the refrigerant by suction before removing the fuel cooler. The safety regulations must be observed during all work on the refrigerant system! (See: 871 Safety regulations when handling refrigerant R134a)

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 with suitable plugs. 3. Disconnect the negative terminal of the battery. WARNING Danger of fire and injury! Observe general safety regulations on the fuel system! Wear protective gloves that are fuelresistant! Ensure that there is adequate ventilation. CAUTION Always counter at the fuel lines when undoing them.

20 68 19 Removing and installing fuel cooler

571

einordnung

4. Undoing fuel lines. Counter union nut with a/f 17 and with a/f 14. 5. Collect residual fuel. Undo holding clamp and remove fuel cooler. top of page

Installing fuel cooler

1. Fit new seals on to 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 refrigerant unit. 5. Warm the engine up to operating temperature and carry out a leak test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing fuel cooler

572

21 10 19 Removing and installing air guide for charge air cooling

Removing air guide for charge air cooling Installing air guide for charge air cooling

top of page

Removing air guide for charge air cooling

Preliminary work: Disassemble the accessories of the rear 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 air cooler. To do this, disconnect the connecting hose between the engine and charge air cooler at the separation point beneath the tail light. Unclip the safety bracket and pull out the hose.

21 10 19 Removing and installing air guide for charge air cooling

573

einordnung Open hose clamp at bottom of charge air cooler and pull off the flange. 3. Remove charge air cooler. To do this, disconnect both hose connections on the charge air cooler. Then unscrew the seven fastening 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 out.

6. Unscrew the four fastening nuts.

7. Pull air guide at the back end downwards and then take out of the body towards the rear. top of page

Removing air guide for charge air cooling

574

einordnung

Installing air guide for charge air cooling

1. Reinstall air guide. Replace all seals on the air guide. Insert the front end of the air guide into the body. Press the back end upwards into the wing.

2. Retighten air guide. Replace the four fastening clips of the intake pipe and tighten the air duct with the four fastening screws .

3. Reinstall 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 to 10 Nm (7.5 ftlb.). 5. Install charge air cooler. Move the charge air cooler back into installation position. Tighten the two rear fastening screws to 10 Nm (7.5 ftlb.). Tighten the three front fastening screws to 10 Nm (7.5 ftlb.). Then fasten the heat shield with two sheetmetal nuts. Installing air guide for charge air cooling 575

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing air guide for charge air cooling

576

21 30 19 Removing and installing turbocharger

Removing turbocharger Installing turbocharger top of page

Removing turbocharger
Preliminary work: Disassemble the accessories of the rear spoiler (includes rear end, lower central heat shield and bumper) 635519 Removing and installing rear spoiler . CAUTION Danger 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 charge air cooler.

2. Then unscrew the two fastening screws and the hexagon nuts on the air charge cooler. 3. Unscrew the rear hexagon nut and the fastening screw.

4. Undo the two fastening nuts on the heat shield. 5. Take the charge air cooler out of the vehicle.

21 30 19 Removing and installing turbocharger

577

einordnung

6. Remove heat shield. Unscrew the heat shield covering the catalytic converter and the turbocharger. Undo the two fastening nuts on the vehicle for this purpose. WARNING Danger of fire! The heat shield should not be bent or deformed. Bent or deformed heat shields must be replaced.

7. Undo oil pipe and turbocharger support. Open and unscrew the upper oil pipe of the turbocharger at the 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. Push a small screwdriver between connection nipple and vacuum hose. Widen vacuum hose a little and spray in silicone spray at the same time. Remove vacuum hose with angled pliers. CAUTION Damage to the control box. Never lever off the hose with a screwdriver.

9. Screw off oil pipes. Open the two oil pipes on the oil container. Collect draining oil.

Removing turbocharger

578

einordnung

10. Undo pressure pipe from turbocharger. Undo the hose clamp and remove the pressure hose from the exhaust turbocharger for this purpose.

11. Unscrew the four fastening nuts on the turbocharger flange to the catalytic 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. top of page

Installing turbocharger
1. Fit turbocharger. Insert a new seal between the turbocharger and the exhaust manifold and tighten the three fastening screws to 30 Nm (22 ftlb.).

Installing turbocharger

579

einordnung

2. Tighten exhaust manifold on the cylinder head. Position exhaust manifold with new seals (cylinder head and on the catalytic converter) on the cylinder head and insert in the exhaust catalytic converter at the same time. Position 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 (24 ftlb.)) according to the sequence shown.

3. Replace the four fastening nuts to the exhaust catalytic converter and tighten to 30 Nm (22 ftlb.).

4. Tighten the two oil pipes to 30 Nm (22 ftlb.) each.

Installing turbocharger

580

einordnung

5. Screw on the turbocharger support. Do not forget the washer beneath the new hexagon nut when doing this. Tighten the hexagon nut to 23 Nm (17 ftlb.). Then position the hexagon nut of the vent line by hand and tighten to 20 Nm (15 ftlb.).

6. Install heat 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. Insert the charge air cooler in the studs on the body. Tighten the rear fastening nut and the two fastening screws to 23 Nm (17 ftlb.). 9. Tighten the front fastening nut and the fastening screw to 23 Nm (17 ftlb.).

Installing turbocharger

581

einordnung

10. Tighten the two sheetmetal nuts on the heat shield. 11. Reconnect the two hose connections. Make sure that the clips are properly inserted when doing this. Press in the hose support until it is heard to engage. 12. Carry out oil level and tightness test. Note Conclude by carrying out oil level and tightness test.

Location Turbocharger on the exhaust manifold Exhaust manifold on the cylinder head 1. stage 2. stage Turbocharger on the exhaust catalytic converter Oil inlet line Oil return line Turbocharger support Oil inlet line on the turbocharger Fastening screws on charge air cooler

Thread M8

Tightening torque Nm (ftlb.) 23 (17 ftlb.) 25 (19 ftlb.) 33 (24.5 ftlb.)

M8 M16 x 1.5 M16 x 1.5 M8 M8

30 (22 ftlb.) 30 (22 ftlb.) 30 (22 ftlb.) 23 (17 ftlb.) 20 (15.0 ftlb.) 23 (17 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing turbocharger

582

21 43 19 Removing and installing the charge air cooler

Removing the charge air cooler. Installing the charge air cooler top of page

Removing the charge air cooler.

Preliminary work: The accesories rear end bumper (Serv. No.: 635519) and the wheel housing liner (Serv.:536919) must be removed. 1. Disconnect the connecting hose between the air cleaner and the charge air cooler. To do so, 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 hose downwards.

3. Undo the front fastening. Unscrew the fastening nut and the two fastening screws.

4. Undo the bolts on the heat shield. Undo the two sheetmetal nuts on the lower end of the heat shield. Then press the heat shield out of the studs. 5. Undo the rear fastening. Unscrew the fastening nut and the fastening screw. 21 43 19 Removing and installing the charge air cooler 583

einordnung 6. Remove charge air cooler. top of page

Installing the charge air cooler

1. Reinstall the shield of the exhaust system. Tighten the two fastening nuts on the side member for this purpose. 2. Install charge air cooler. To do so, place the charge air cooler back in the vehicle.

3. Tighten the front two fastening nuts and the fastening screw in the wheel 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 Orings and fit them in place. The connections must audibly engage.

5. Tighten the two sheetmetal nuts on the heat shield. Reinstall the rear spoiler. Location Fastening screws and nuts of the charge air cooler Thread M8 Tightening torque Nm (ftlb.) 23 Nm (17 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Removing the charge air cooler. 584

21 67 05 Checking and adjusting the bypass flap control boxes on the turbocharger
Check and adjust (cylinder bank 1 3) Check and adjust (cylinder bank 4 6)

Item A B C

Designation of the special tool Dial gauge holder VW 387 Tester 9160/1 Pressure gauge 9103/2

Explanation

Use boost pressure gauge from 944 Turbo

top of page

Check and adjust (cylinder bank 1 3)

Test
1. Raise the vehicle at the prescribed jacking points.

2. 21 67 05 Checking and adjusting the bypass flap control boxes on the turbocharger 585

einordnung Fasten special tooldial gauge holder VW 387 onto the underneath of the camshaft housing (cylinder bank 13). Flanges with thread M 8 have been provided or this procedure. 3. Align tracer pin with push rod, set the dial gauge with pretension to 0. 4. Connect special tool pressure gauge 9103/2 . Connect hand pump and pressure gauge together with branch pieces. Hang pressure gauge on stabilizer. 5. Remove vacuum hoses from the control box: Push a small screwdriver between connection nipple and vacuum hose. Widen vacuum hose a little and spray in e.g. silicone spray at the same time. Pull off vacuum hose.

6. Connect connecting piece (shopmade) and Tecalan line (shopmade) onto the control box and connect with the pressure gauge. 7. Produce overpressure of 0.5 bar with special tool tester 9160/1 . Read off pressure on special tool pressure gauge 9103/2 . Have a second person read off the stroke of the push rod on the dial gauge at the same time. Prescribed stroke: 4 0.5 mm.

Adjusting
1. Remove safety bracket. 2. Twist adjusting nut accordingly. Turning clockwise stroke smaller. Turning counterclockwise stroke larger. 3. Fit safety bracket again. top of page

Check and adjust (cylinder bank 4 6)

Test

586

einordnung

1. Fasten special tool dial gauge holder VW 387 onto the underneath of the right camshaft housing. 2. Make tracer pin (shopmade). 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 13.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Check and adjust (cylinder bank 4 6)

587

21 67 19 Removing and installing bypass flap control box on the turbocharger Engine installed
Removing bypass flap control box on the turbocharger Installing bypass flap control box on the turbocharger top of page

Removing bypass flap control box on the turbocharger

CAUTION Danger of burns! Parts of the exhaust system can be extremely hot. Do not begin work until the 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 the nut on the push rod, and pull the push rod out of the release.

3. Remove vacuum hose from the control box. Push a small screwdriver between connection nipple and vacuum hose. Widen vacuum hose a little and spray in silicone spray at the same time. Pull off vacuum hose.

21 67 19 Removing and installing bypass flap control box on the turbocharger Engine installed 588

einordnung 4. Undo and unscrew the two holder screws of the control box. 5. Remove control box. top of page

Installing bypass flap control box on the turbocharger

1. Push the push rod of the control box 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 => Checking and adjusting the bypass flap control boxes on the turbocharger.

5. Push the vacuum hose on to the control box.

Removing bypass flap control box on the turbocharger

589

einordnung 6. Fit the safety bracket again, and check for correct seating.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing bypass flap control box on the turbocharger

590

21 75 20 Removing and installing oil container for exhaust turbocharger Engine installed
Removing oil container for exhaust turbocharger Installing oil container for exhaust turbocharger top of page

Removing oil container for exhaust turbocharger

WARNING Danger of scalding from draining oil! Danger of burns! Parts of the exhaust system can be 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 shields must be replaced. Requirement: Remove rear spoiler 635519 Removing and installing rear spoiler .

1. Remove heat shield 635019 Removing and installing rear bumper .

2. Unscrew the oil drain plug arrow of the oil container and collect any emerging oil.

21 75 20 Removing and installing oil container for exhaust turbocharger Engine installed

591

einordnung

3. Unscrew the M6 screw on the heat shield arrow .

4. Undo both union nuts of the oil 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. Remove oil container.

Removing oil container for exhaust turbocharger

592

einordnung

Note

Always replace the oil sealing ring arrow and the sealing ring for the oil drain plug!

top of page

Installing oil container for exhaust turbocharger

1. Place 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. Place the upper oil line in position and tighten both union nuts. Tightening torque 30 Nm (22 ftlb.)

Installing oil container for exhaust turbocharger

593

einordnung

4. Tighten the M6 screw arrow of the line holder. Tightening torque 10 Nm (7.5 ftlb.)

5. Fit the heat shield using the M6 screw arrow . Tightening torque 10 Nm (7.5 ftlb.)

6. 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 Changing engine oil and filter .

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing oil container for exhaust turbocharger

594

21 80 19 Removing and installing oil pump for turbocharger

Tools Removal Installation 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 page

Removal

21 80 19 Removing and installing oil pump for turbocharger

595

einordnung

No. Designation 1 Panhead screw M6 x 16 2 Oilpump cover 3 Oring 68 x 2 4 Oil pump gear 1 5 Oil pump gear 2 6 Oring 7 Bracket 8 Oring 28.0 x 4.5 9 Connection fitting 10 Dust protection ring

Qty. Removal Installation 4 When tightening, simultaneously check operating smoothness of the oil pump. 1 Check for signs of scoring 1 Replace; ensure correct position Grease with Optipit Grease with Optipit Replace; apply a thin coat of Vaseline 4 2 2 Replace; coat with coolant Check, replace if necessary

1. Raise the vehicle at the prescribed jacking points. 2. Disconnect battery. 3. Open engine compartment lid. 4. Remove rear spoiler. Serv. No.: 63 55 19 5. Remove bumper with shield.

Removal

596

einordnung 6. Remove lateral shields.

7. Loosen fastening nuts.

8. Loosen fastening nuts on the turbocharger. Remove the shield.

9. Detach restraining straps. Undo the two restraining straps on the rear muffler. Loosen the two hexagon socket screws for this 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. Push restraining straps out of the holder. Press the restraining strap into the recesses on the engine carrier using a screwdriver and move outwards.View from engine side 11. Remove rear muffler. Two persons can now remove the rear muffler.

12. Undo fastening screw M 6 x 34 on the air cleaner housing. Removal 597

einordnung 13. Undo hose clamp between the air cleaner housing and intake manifold.

14. Tilt the complete air cleaner housing 90 upward and then remove from the engine compartment. 15. Pull of the connecting hoses between the charge air coolers and the pressure 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 hexagonhead bolts. Pull off the electrical plug.

17. Disconnect oxygen sensor plug on the rear closing panel.

18. Disconnect oxygen sensor plug. 19. Undo the three fastening screws of the belt pulley on the hydraulic system pump by approx. 1/2 turn.

Removal

598

einordnung

20. Relieve drive belt. To do this turn the tensioning roller clockwise, hold and simultaneously remove the drive belt. 21. Remove pulley from the hydraulic pump.

22. Remove generator. 23. Disconnect the hydraulic lines with plugin coupling on the expansion tank. Note 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 between lines and the red unlocking ring and unlock by pulling black line to the right and simultaneously pressing the tool against the red unlocking ring. 25. Unscrew two fastening screws (M8 x 25) with hexagon socket head bolts on the tank.

Removal

599

einordnung

26. Unscrew three M8 screws and one M6 screw between the hydraulic pump and the console. Pull the expansion tank with hydraulic pump out of the bracket and suspend on the side. 27. Detach the air conditioning compressor and remove the bracket. To do this, disconnect the electrical plug connection, remove the compressor 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 pivot the throttle body upward. Undo the fastening screws and remove the throttle body.

30. Unscrew closure cap of coolant expansion tank. Undo coolant drain plugs on right and left and drain the coolant. 31. Equip drain plugs with new sealing rings. Tightening torque: 10 to 15 Nm (7.5 to 11.0 ftlb.).

Removal

600

einordnung

32. Pull off the right and left coolant hoses. Lever off the locking clip for this purpose.

33. Refit the locking clip on the coolant neck.

34. Remove bracket for generator. Undo hexagonhead bolts.

35. Loosen coolant neck.

36. Undo coolant hoses over the coolant pump.

Removal

601

einordnung Note Tip for easier assembly! The coolant hoses are easier to remove when the complete bracket is removed later.

37. Loosen the stabilizer at top and swivel it downward. Note When swivelling, make sure not to damage the bellows on the lower joint!

38. Support the enginetransmission unit. Fasten special tool (retaining device) 9624/1 on the takeup points of the stabilizer mounts. The pressure disc must rest on the crankcase or crash support. 39. Separate engine carrier from the engine mounts (wrench size 18).

40. Loosen engine carrier on the bracket.

Removal

602

einordnung

41. Secure the bracket with a shorter auxiliary screw (M10 x 55).

42. Detach the oil supply line from the bracket (righthand side).

43. Detach the oil supply lines from the bracket (lefthand side).

44. Remove auxiliary screw again. 45. Remove complete bracket. Simultaneously pull off coolant hoses.

46. Undo oil pump fastening screws and remove the cover. Removal 603

einordnung 47. Check oil pump cover and contact surface of the oil pump gears in the bracket for signs of seizing or excessive wear. The entire bracket must be replaced if necessary. The bracket, oil pump gear and oil pump cover are matched. top of page

Installation
1. Grease oil pump gears and contact surfaces with Optipitt assembly grease. Make sure that grease does not enter the receiving bores for the dowel pins.

2. Insert oil pump gears in the housing. The allround groove of the outer oil pump gears must face the oil pump cover.

3. Fasten oil pump cover. When tightening, simultaneously check the operating smoothness of the oil pump. Tighten the screws crosswise to 10 Nm (7.5 ftlb.). Tightening torque 10 Nm (7.5 ftlb.).

4. Prepare bracket for installation. Unscrew plug (Torx T30). 5. Fit new Oring on the oil pump cover and new Orings on the lower coolant connection flanges. Apply a thin coat of Vaseline on the Orings.

Installation

604

einordnung

6. Position bracket on the crankcase and simultaneously use a screwdriver to connect the oil pump drive shaft and the intermediate shaft. Do not use excessive force; gently press in place by hand.

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 the Orings.

8. Apply Loctite 574 on the thread of the plug and fasten the plug. Tightening torque 4 Nm (3.0 ftlb.).

9. Fit oil lines for the righthand side. Use new Orings.

Installation

605

einordnung

10. Fit oil lines for the lefthand side. Use new Orings.

11. Fit coolant lines over the coolant pump. Use water or coolant 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. Fasten engine carrier on the engine mounts (wrench size 18). Tightening torque: 85 Nm (63 ftlb.).

Installation

606

einordnung

15. Remove special tool (retaining device) 9624/1 . 16. Fasten stabilizer.

17. Install rear mufflers with new seals. The seals between the exhaust turbochargers and the rear muffler must be replaced. Move the rear muffler into installation position and push the two tensioning straps over the holder on the engine carrier. Subsequently tighten the two hexagon socket head bolts slightly.

18. Push the 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. Fit heat shields, bumper and rear spoiler.

21. Install bracket for the generator. Replace the four Orings on the two connecting flanges between the two coolant outlet necks of cylinder bank 13. Then screw in the four fastening screws. Important: The front right screw must be inserted with Loctite 574 (as shown in the illustration). Tightening torque 65 Nm (48 ftlb.). Installation 607

einordnung

22. Check whether locking clips are properly seated. 23. Fit coolant hoses. Always replace Orings on the coolant hoses. Wet Orings with plenty of water. Note Never fit dry; only use water.

24. Push on coolant hose. Align the flange of the coolant hose as shown in the illustration (lug/groove). Press the coolant hose firmly against the connection neck. The coolant hose must engage audibly. Then recheck whether it is fitted properly by tilting and pulling on it. 25. Fit airconditioning compressor. Do not forget the spacer sleeve. 26. Install throttle body. 27. Install generator. 28. Install hydraulic pump. 29. Fit drive belt (service No.: 13 78 19). 30. Install air cleaner assembly. 31. Bleed the cooling system. Use the Porsche System Tester 2 for this purpose. Select the "Special functions" menu 32. Bleed the steering system. (Group 48) 33. Bring the engine to operating temperature and check it for leaks.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

608

21 90 19 Removing and installing pressure sensor

Removal Installation top of page

Removal

1. Undo hexagonhead bolt and pull pressure sensor out of the pressure 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 hexagonhead bolt (M6 x 16) and tighten to 10 Nm (7.5 ftlb). 2. Fit plug. The plug should engage audibly.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

21 90 19 Removing and installing pressure sensor

609

24 00 33 Completing the vacuum connections

24 00 33 Completing the vacuum connections

610

einordnung

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Recirculating air valves Tpiece Recirculating air valve hose Air hose Recirculating air valve hose Pipe 5 x 1 x 250 Curved hose Pipe 5 x 1 x 245 Fourway branch piece Pipe 5 x 1 x 250 Threeway branch piece Pipe 4 x 1 Distributor pipe Vacuum accumulator Combination valve for secondary air 611

24 00 33 Completing the vacuum connections

einordnung 16 17 18 19 20 21 22 Fuel pressure regulator Electric switchover valve for secondary air Pipe 4 x 1 x 350 Pipe 4 x 1 x 500 Pipe 4 x 1 x 500 Curved protective hose 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, 996451, 996620, 996621, 996650, 996651, 996840, 996841

24 00 33 Completing the vacuum connections

612

24 25 19 Removing and installing air cleaner

Removing air cleaner Installing air cleaner top of page

Removing air cleaner

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 the same time.

2. Pull off the connecting hose between the left turbocharger and the intake pipe. To do this, unclip the retaining clips using a screwdriver and pull out the hose. Refit the retaining clips immediately.

24 25 19 Removing and installing air cleaner

613

einordnung

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 pipe.

5. Tilt air cleaner housing outwards. To do this, 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 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 of the engine compartment.

7. Open air cleaner housing. To do this, open the new captive screws and pull the two housing halves apart. 8. Take out the cleaner element. Take out the air cleaner element. Wipe out the two housing halves with a cloth. top of page

Removing air cleaner

614

einordnung

Installing air cleaner

1. Insert filter element. Insert the filter element into the cleaned air cleaner housing. Retighten the two air cleaner housing halves with the new captive screws. 2. Clip in hot film mass 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 and move into installation position. To do this, first turn the housing to the right by approx. 90 and push the rubber hose over the flange. Then swivel downwards by 90.

Installing air cleaner

615

einordnung

4. Tighten the fastening screw M6x34 to 10 Nm (7.5 ftlb.).

5. Tighten the hose clamp on the connecting hose. Reconnect 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!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing air cleaner

616

24 42 19 Removing and installing throttle body Engine installed

Removing throttle body Installing throttle body top of page

Removing throttle body

1. Remove air cleaner housing => Removing and installing air cleaner. 2. Pull off the pressure hoses between the charge air coolers and the Yshaped pressure pipe. To do this, unclip the retaining clips using a screwdriver and pull out the hose. Refit the retaining clips immediately. 3. Detach the holder over the airconditioning compressor. Unscrew the M6 screw on the holder for this purpose.

4. Undo the hose of the Yshaped pressure pipe. To do so, undo the spring band clamp arrow and pull the hose off the Yshaped pressure pipe.

5. Remove the Yshaped pressure pipe. To do so, undo the spring band clamp 3 and the hexagonhead bolts 1 and 2 . Disconnect pressure sensor plug 4 . 6. Undo the rubber air cowl between the pressure pipe and the throttle body. To do so, open the screwtype hose clamp on the throttle body side and remove the rubber air cowl.

24 42 19 Removing and installing throttle body Engine installed

617

einordnung 7. Disconnect the connector at the throttle potentiometer top arrow and unscrew the four M6 screws arrows . 8. Remove the throttle body. top of page

Installing throttle body

Note Always replace the seal between the intake distributor and the throttle body! 1. Insert seal into the intake distributor.

2. Position the throttle body on the intake distributor and position and tighten the four M6 screws arrows . Tightening torque of M6 screws = 10 Nm (7.5 ftlb.)

3. Position the Yshaped pressure pipe with the rubber air cowl on the throttle body, connect the vacuum hose 3 and fasten the spring band clamp. Connect the connector of the pressure sensor 4 and position and tighten the M6 screws 1 and 2 . Tightening torque of M6 screws = 10 Nm (7.5 ftlb.) 4. Install the holder over the airconditioning compressor. Position and tighten the M6 screw in the holder for this purpose. Tightening torque of M6 screw = 10 Nm (7.5 ftlb.)

Removing throttle body

618

einordnung 5. Connect hose to the Yshaped pipe and fasten with the spring band clamp arrow . 6. Install the pressure hoses between the charge air coolers and the Yshaped pressure pipe; the pressure hoses must engage audibly. 7. Install air cleaner housing => Removing and installing air cleaner.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing throttle body

619

24 46 01 Testing the intake distributor (leak test)

Tools Leak test top of page

Tools

Item Designation of the special tool Plug 9264/6

Explanation 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 air cleaner housing.

24 46 01 Testing the intake distributor (leak test)

620

einordnung

2. Undo rear hose clamp between the air cleaner housing and intake manifold.

3. Tilt the complete air cleaner housing 90 to the left and remove to the rear. 4. Push rubber sleeve of special 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 once the pressure has built up; smaller leaks can be made visible with a leaklocating spray.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Leak test

621

24 46 20 Removing and installing intake distributor Engine removed

Note Removing intake distributor Installing intake distributor Note Pay attention to the routing of the vacuum hoses! => Completing the vacuum connections Pay attention to the storage of the individual parts! => Disassembling 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 => Removing and installing throttle body Engine installed.

3. Undo the 2 spring band clamps and the screwtype hose clamp arrows and pull off the hoses.

4. Unclip the vacuum line arrow on the strain relief strut.

24 46 20 Removing and installing intake distributor

Engine removed

622

einordnung

5. Pull the three vacuum hoses arrows off the intake distributor.

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 overrun air valve module.

9. Removing intake distributor 623

einordnung Remove the activated carbon filter lead. To do so, disconnect the plug connection on the bleeder valve arrow and disconnect the coupling on the pressure pipe. 10. Undo the six upper screwtype hose clamps on the rubber sleeves of the intake distributors.

11. Disconnect all vacuum leads at the fourway branch piece. Note All rubber sleeves must be 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. Coat the inside of the rubber sleeves slightly with Vaseline. Place intake distributor into rubber sleeves and press into place evenly as far as the stops without tilting.

2. Connect all the vacuum leads at the fourway branch piece. 3. Tighten the six upper screwtype hose clamps on the rubber sleeves.

Installing intake distributor

624

einordnung

4. Install the activated carbon filter lead. To do so, connect the plug connection on the bleeder valve arrow and the coupling on the pressure pipe.

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. Position and tighten the M6 screw arrow for this purpose. Tightening torque of M6 screw = 10 Nm (7.5 ftlb.)

Installing intake distributor

625

einordnung

8. Connect the three vacuum hoses arrows on the intake distributor.

9. Clip the vacuum line arrow on to the strain relief strut.

10. Connect the three hoses to 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 => Removing and installing secondary air pump.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing intake distributor

626

24 46 37 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 distributor

627

einordnung

1 Left intake distributor 2 Right intake distributor 3 Closure cap with strut 4 Hose clamp 70 to 90 5 Rubber sleeve 80 with two hose clamps 80 to 100 6 Throttle with Egas actuator 7 Fastening screws M6 x 50 8 Hexagonhead bolt M6 x 12 9 Hexagonhead bolts M6 x 12 10 Hexagonhead bolts M6 x 18 11 Holder for intake air distributor pipe 12 Strain relief strut 13 Distributor pipe 1. Unscrew screws no. 8 and no. 10 and remove the strain relief. Disassembling the intake distributor 628

einordnung 2. In each case, undo the two hose clamps on the left and right of the distributor pipe and push the rubber sleeves as far as possible 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 2 3 4 5

Recirculating air valves Tpiece Recirculating air valve hose Air hose Recirculating air valve hose 629

Vacuum lines

einordnung 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Pipe 5 x 1 x 250 Curved hose Pipe 5 x 1 x 245 Fourway branch piece Pipe 5 x 1 x 250 Threeway branch piece Pipe 4 x 1 Distributor pipe Vacuum accumulator Combination valve for secondary air Fuel pressure regulator Electric switchover valve for secondary air Pipe 4 x 1 x 350 Pipe 4 x 1 x 500 Pipe 4 x 1 x 500 Curved protective hose 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, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Vacuum lines

630

24 69 19 Precautionary measures when handling oxygen sensors

Caution CAUTION Oxygen sensor can be damaged if handled improperly. Do not remove the plastic cap on the thread until just prior to fitting the oxygen sensor. The thread grease must under no circumstances come into contact with the connector. Protect sensors before and after fitting against mechanical shocks. Sensors that were dropped on the floor must not be used owing to the risk of a broken ceramic insulator. The cables must not be twisted or kinked when the sensors are screwed in. Avoid pulling on the cable 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, the connector must be protected against any and all types of soiling. Sensors with soiled or damaged connector must no longer be used. Protect the cables and plugs when transporting the exhaust system with the sensors already fitted. Highpressure cleaning equipment must not be used in the area of the sensors and plug connections. Contact and corrosion agents, e.g. Stabilant, must not be applied on the plug contacts of the oxygen sensors.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

24 69 19 Precautionary measures when handling oxygen sensors

631

24 73 19 Removing and installing oxygen sensors behind catalytic converter

Removing oxygen sensors behind the catalytic converter Installing oxygen sensors behind the catalytic converter For tools, refer to Service No. 24 69 19 : Removing and installing oxygen sensors in front of the catalytic converter.

Illustration shows 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 front of catalytic converter with plastic clip (rectangular) 2 Plug for sensor behind catalytic converter (oval) Note Observe precautionary measures when using oxygen sensors !

top of page

Removing oxygen sensors behind the catalytic converter

24 73 19 Removing and installing oxygen sensors behind catalytic converter

632

einordnung

Oxygen sensor, left side :

1. Remove air cleaner housing => Removing and installing air cleaner

2. Separate the oval plug connection for the oxygen sensor behind the catalytic converter in the left engine compartment 2 . 3. Unclip the oxygen sensor wire behind the catalytic converter from the wire retainer and the sheetmetal clips. Note Always expose oxygen sensor wire so that the wire can turn when unscrewing the 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 rectangular plug connection for the oxygen sensor behind the catalytic converter 2 . 3. Unclip the oxygen sensor wire behind the catalytic converter from the wire retainer and the sheetmetal clips. Note Always expose oxygen sensor wire so that the wire can turn when unscrewing the sensor. 4. Undo and unscrew oxygen sensor with a spanner or an open ring wrench (a/f 22). top of page

Oxygen sensor, left side :

633

einordnung

Installing oxygen sensors behind the catalytic converter

Install the oxygen sensors in reverse order. Note Always expose oxygen sensor wire so that the wire can turn when screwing in the sensor. 1. Position the oxygen sensor by hand and screw in as far as possible. 2. Tighten oxygen sensor with conventional open ring wrench Hazet 46811 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 the left and right. 4. Close the oval plug connection. 5. Install the air cleaner housing again => Removing and installing air cleaner.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing oxygen sensors behind the catalytic converter

634

26 01 05 Exhaust system leak test

Caution Tools Leak test CAUTION The permissible maximum pressure for performing the leak test 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 leak test

Clamp setting : Rubber seal compressed

Item Special tool designation 1

Remarks

26 01 05 Exhaust system leak test

635

einordnung Plug 9710/1 for 911 Turbo (996) Leak detection spray Gr. 2.2; Workshop Equipment Manual ; order replacement seals from the manufacturer (specification on the bottom of the plug) e.g. test spray TPS674, Messrs. TEGA, Wrzburg

top of page

Leak test

1. Fit plugs in exhaust tailpipes on the rear muffler see Figure . Insert plugs into tailpipe outlets. To adapt the diameter (seating surface of rubber seal), turn each handle clockwise or counterclockwise until the tailpipe outlets are airtight by throwing the adapter handle through 90. Note Do not exceed the permissible pressure of 1 bar !

2. Connect pressure gauge to a valve and pressurize the exhaust system to 1 bar overpressure see Figure . 3. Wet individual disconnection points of the exhaust system (e.g. manifold flange, clamping sleeves) with test spray to make any leaks visible. Repeat test procedure if necessary. 4. Remove pressure gauge and both plugs.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tools

636

26 33 19 Removing and installing rear 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 and installing rear mufflers

637

einordnung

1. Unscrew rear muffler from the turbocharger. Unscrew the four fastening nuts on the left and right for this purpose.

2. Disconnect oxygen sensors. Disconnect and disengage the four plugs at the rear of the closing panel for this purpose.

3. Detach restraining straps. Undo the two restraining 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 hold it up.

4. Push restraining straps out of the holder. Press the restraining strap into the recesses on the engine carrier using a screwdriver and move outwards.View from engine side 5. Remove rear muffler. Two persons can now remove the rear muffler.

Removing rear mufflers

638

einordnung top of page

Installing rear mufflers

1. Install rear mufflers with new seals. The seals between the exhaust turbochargers and the rear muffler must be replaced. Move the rear muffler into installation position and push the two tensioning straps over the holder on the engine carrier. Then slightly tighten the two hexagon socket head bolts.

2. Screw down the rear muffler on the exhaust catalytic converters. To do this, replace the four fastening 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 hexagon socket screws to 15 Nm (11 ftlb.). 4. Connect oxygen sensors. Reconnect the four oxygen sensor cables and clip them in. To conclude: Install bumpers, centre heat shield and rear spoiler 635519 Removing and installing rear spoiler . Check exhaust system for leaks. Location Screw connection on turbocharger flange Restraining strap on rear muffler Installing rear mufflers Thread M8 M6 Tightening torque Nm (ftlb.) 30 (22) 15 (11) 639

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing rear mufflers

640

26 65 19 Removing and installing secondary air pump

Removal Installation top of page

Removal

1. Pull off right connecting hose between charge air cooler and pressure pipe: Unclip the locking clips using a screwdriver and pull off the hose. Then reclip the locking clips onto the pressure pipe. Ensure correct seating.

2. Remove switchover valve on the secondary air pump: In order to do this, press the locking tabs of the holding clip with a screwdriver in the direction of the secondary air pump and at the same time push the switchover valve to the right and remove. Undo upper fastening screw M6 x 10.

26 65 19 Removing and installing secondary air pump

641

einordnung

3. Undo lower fastening screw M6 x 10. 4. Disconnect the electrical plug connection. Undo air hose and pull off. 5. Lift the secondary air pump out of the engine compartment. top of page

Installation
1. Install secondary air pump. Install plug connection and air hose. 2. Fasten secondary air pump housing with two hexagonhead bolts M6 x 10. 3. Clip switchover valve onto the secondary air pump housing. 4. Fix a new Oring onto the right pressure hose and coat the Oring and takeup bore with plenty of water.

5. Push the pressure hose into the pressure pipe. The pressure hose must engage with an audible click. 6. Check that the pressure hose has been fitted correctly by tipping and pulling on the pressure hose.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removal

642

27 22 19 Removing and installing threephase generator

Note Removing the threephase generator Installing the threephase generator Undoing and tightening the belt pulley Tool for holding the freewheel pulley Note When the engine is being cleaned with highpressure cleaning equipment, make sure that the high pressure blast is not directed directly onto the threephase generator (risk of bearing damage).

top of page

Removing the threephase generator

1. Disconnect the battery and cover terminal or battery. 2. Remove the complete air cleaner assembly. Undo the fastening screw for the air cleaner housing and the hose clamp on the air flow sensor. 3. Undo the hose on the charge air cooler at the left and right on the pressure pipe. 4. Disconnect 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 and remove the belt. 7. Remove the deflection roller under the threephase generator. 8. Disconnect the cable lug of the B+ lead to the threephase generator at the B+ disconnection point.

9. Undo left fastening screw (in direction of travel) and remove. 10. Undo right fastening screw by three turns. 11. A gentle tap on the fastening screw loosens the threaded bushing in the threephase generator arm (use aluminum mandrel). Unscrew fastening screw. 12. Remove threephase generator and carefully pull a little to the rear. 13. Press the plug connection towards the threephase generator housing, release and pull off. 14. Remove the threephase generator towards the rear and disconnect the B+ lead. 27 22 19 Removing and installing threephase generator 643

einordnung top of page

Installing the threephase generator

1. Fasten B+ lead and install threephase generator.

2. The B+ lead must be fastened onto the long wiring arrangement (arrow) of the threephase generator (see Figure). 3. Install deflection roller and fit drive belt. Tightening torque of the hexagon nut M16 x 1.5: 65 5 Nm (48 3.5 ftlb) Tightening torque of the hexagonhead bolts M10: 46 Nm (34 ftlb.) Tightening torque of the M8 hexagon nut: 15 Nm (11 ftlb.) Tightening torque of the deflection roller M10: 46 Nm (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 tightened using a standard commercially available tool. Double offset ring wrench a/f 24 Screwdriver insert for internal serration screw a/f 10 Cross handle and torque wrench 1. The hexagon nut a/f 24 must be countered with the ring wrench during tightening. 2. The shaft is tightened to the prescribed tightening torque of 65 5 Nm ( 48 3.5 ftlb.) using the screwdriver insert and the torque wrench. top of page

Tool for holding the freewheel pulley

Note

Removing the threephase generator

644

einordnung Only for vehicles with manual transmission! 1. Use an a/f 17 multipletooth adapter to hold the freewheel pulley.

2. A/f 17 multipletooth adapter: see Workshop Equipment Manual, chapter on commercially available tools, No. 321. 3. Counter with a double ring wrench when tightening with the a/f 17 multipletooth adapter. 4. The shaft is tightened to the prescribed tightening torque of 80 5 Nm (59 3.5 ftlb.) using the screwdriver insert (a/f 10 internal serration screw) and torque wrench.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Tool for holding the freewheel pulley

645

27 27 19 Removing 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 for generator 646

einordnung Risk of short circuit with battery connected The battery must be disconnected before any work is carried out on the engine. 1. Drain coolant. Open cap of coolant expansion tank. Unscrew coolant drain plugs on left and right and drain the coolant. After draining the coolant, fit new sealing rings on the drain plugs.

Drain plug tightening torque: 10 to 15 Nm (7.5 to 11 ftlb.)

2. Remove air cleaner housing. Undo hexagonhead bolt M6 x 34. Undo the hose clamp on the throttle body. Remove connector from hot film 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 lay it aside. Detach the holder from the oil filler neck.

5. Undo fastening screws on the expansion tank upper arrows (two M8 screws) and the four screws lower arrows (three M8 screws and one M6 screw) on the hydraulic pump. Pull the expansion tank with hydraulic lines and with connected lines up out of the fastening bracket and lay aside to the righthand side. 6. Remove holder for oil filter bracket. Unscrew the M6 screw and undo the M8 screw for this purpose. Lift the holder out.

Removal

647

einordnung

7. Separate the B+ disconnection point arrow under the cover for this purpose. Unscrew the left fastening screw. Unscrew the right fastening screw by approx. 1 cm. Then drive it in with gentle taps of a hammer until the screw head makes contact with the generator again. Now unscrew fastening screw completely. Lift the generator upwards out of the engine compartment. 8. Remove air conditioning compressor from the bracket for the generator. Unscrew the three screws arrows for this purpose. The throttle body can be swung upward for better accessibility 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 compressor. Lift the compressor out of the engine compartment and lay it aside with the leads still connected. Protect the body from damage with a cover.

10. Unclip coolant hose. To do this, unclip the safety bracket on the coolant neck with a screwdriver and pull the coolant hose up and out. 11. Detach the coolant outlet neck of cylinder bank 4 to 6. Undo the two hexagonhead bolts on the coolant outlet neck for this purpose.

12. Detach bracket for generator. Unscrew the four fastening screws arrows on the bracket for the generator.

Removal

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einordnung

13. Pull off the hose clamp arrow on the coolant connecting hose. Take bracket for the generator out of the engine compartment upward and to the right. 14. Separate bracket for the generator. The bracket can be disassembled in the event of leaks. Unscrew the three screws arrows for this purpose. Pull the two parts apart. Make sure that the two dowel sleeves are not lost. Use a new Oring with 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 the four Orings on the connecting sleeves between the two coolant outlet necks and the bracket for the generator. Insert the bracket into the coolant outlet neck of cylinder bank 1 to 3 from the righthand side. Then screw in the four fastening screws. Tightening torque: 65 Nm (48 ftlb.) Note

Insert the front right screw inset with Loctite 574.

Installing bracket for generator

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einordnung

2. Push on the coolant connecting hose between the oil/coolant heat exchanger and the bracket again and tighten the hose clamp arrow . 3. Fit coolant outlet neck of cylinder bank 4 to 6. Insert the neck with the connecting sleeve into the bracket for the generator for this purpose. Tighten the two fastening screws on the coolant outlet neck. Tightening torque: 10 Nm (7.5 ftlb.)

4. Insert retaining clip. Insert the retaining clip arrow into the groove provided as shown. Replace the Oring on the coolant hose.

5. Push on coolant hose. Align the connection neck of the coolant hose as shown in the illustration. lug/groove arrow Press the coolant hose firmly against the connection neck. The clip must audibly engage. Pull the hose slightly to check for secure seating. 6. Fit airconditioning compressor. To do this, move the compressor into installation position. Tighten the three fastening screws arrows of the air conditioning compressor.

Tightening torque: 23 Nm (17 ftlb.) 7. Installing bracket for generator 650

einordnung Install generator. Return the generator to its mounting position. Connect plug connection and connect the B+ line. Tightening torque for M8 hexagon nut: 15 Nm (11 ftlb.)

Tightening torque for M10 hexagonhead bolt: 46 Nm (34 ftlb.) 8. Install holder for oil filter bracket. To do this, push in the holder in downward direction. 9. Install hydraulic pump. Return the hydraulic pump with connected lines to its installation position and tighten the fastening screws arrows . Tightening torque for M8 fastening screws: 23 Nm (17 ftlb.) Tightening torque for M6 fastening screw: 10 Nm (7.5 ftlb.)

Tightening torque for M8 fastening screw on 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 Removing and installing drive belt. 12. Install air cleaner housing. Refit air cleaner housing into the mounts in the body. Tighten hexagonhead bolt. Tighten the hose clamp on the throttle body and push the plug onto the hot film mass air flow meter.

Tightening torque for hexagonhead bolt M6 x 34: 10 Nm (7.5 ftlb.) 13. Connect battery. Reconnect the battery ground cable. 14. Fill in coolant. Fill in coolant through the expansion tank. Carefully bleed the vehicle 193817 Draining and topping up with coolant.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 Installing bracket for generator 651

27 60 19 Removing and installing starter (manual transmission)

Removing the starter Installing the starter top of page

Removing the starter

1. Disconnect the battery and cover terminal or battery. 2. Pull back protective cap on the solenoid switch and undo terminal 30 lead (M8 nut) and terminal 50 (M6 nut). 3. Undo the upper fastening screw. To do this, use the 3/8 inch tool. Tools: Hexagon socket wrench insert a/f 15 Universal joint Two short extensions Cross handle or ratchet 4. Undo the lower fastening screw. 5. Remove the starter from the holder and turn so that 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 battery and B+ lead from the engine to the B+ disconnection point to terminal 30 (M8 nut) on the solenoid switch. 2. Fasten terminal 50 lead (M6 nut) to the solenoid switch. Tightening torque for M8 hexagon nut: 15 Nm (11 ftlb.), M6 screw: 6.5 Nm (5 ftlb.) Tightening torque of the hexagonhead bolt M10: 46 Nm (34 ftlb.) 3. Push protective cap over the solenoid switch and engage in the B+ lead. 4. Connect the battery and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

27 60 19 Removing and installing starter (manual transmission)

652

28 39 19 Removing and installing hall sender Engine installed

Caution Removing hall sender Installing hall sender Tightening torques WARNING Danger of burns! Parts of the exhaust system can be extremely hot. Do not begin work until the exhaust system has cooled down or wear suitable protective gloves! Danger of fire! The heat shield should not be bent or deformed. Bent or deformed heat shields must be replaced! Note The work procedures apply to both sides of the vehicle.

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Removing hall sender

Preliminary work: Remove rear spoiler. 635519 Removing and installing rear spoiler 1. Remove charge air cooler. => Removing and installing the charge air cooler WARNING Danger of fire! The heat shield should not be bent or deformed. Bent or deformed heat shields must be replaced!

2. Remove side heat shield by undoing the bolts on the heat shield. Undo the two sheetmetal nuts on the lower end of the heat shield. Then, press the heat shield out of the studs. See partial description in chapter 635019 Removing and installing rear bumper.

28 39 19 Removing and installing hall sender Engine installed

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einordnung

Sheetmetal nuts on heat shield 3. Remove the shields above the plug coils. Unscrew the two hexagonhead bolts for this purpose. 4. Disconnect plug connection on hall sender by pressing the cable connector up using a long screwdriver, if necessary.

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 microencapsulated and so must always be replaced! Replace sealing ring on hall sender.

1. Place new sealing ring over the hall sender, position hall sender, then screw in and tighten the new hexagon socket head bolt. Tightening torque: 10 Nm (7.5 ftlb.) Removing hall sender 654

einordnung 2. Clip in cable plug for hall sender using both hands. 3. Fit the shields above the plug coils. Screw in the two hexagonhead bolts for this purpose. Tightening torque: 10 Nm (7.5 ftlb.) WARNING Danger of fire! The heat shield should not be bent or deformed. Bent or deformed heat shields must be replaced!

4. Install heat 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 rear spoiler. 635519 Removing and installing rear spoiler top of page

Tightening torques

Location Hall sender bolts Heat shield ignition coils

Thread M6 M6

Tightening torque [Nm] (ftlb.) Replace; 10 (7.5) 10 (7.5)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing hall sender

655

28 70 55 Replacing the spark plugs

Removing spark plugs Installing spark plugs top of page

Removing spark plugs

Item Designation A Spark plug wrench

Special tool Explanation 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 shield 635519 Removing and installing rear spoiler . 2. Lift the vehicle. 3. Remove charge air cooler.

28 70 55 Replacing the spark plugs

656

einordnung 4. Remove shields. Remove the shields located above the exhaust system. 5. Remove shield. Remove the shields above the plug coils. Unscrew the two hexagonhead bolts 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 . top of page

Installing spark plugs

1. Put on spark plugs by hand.

2. Tighten spark plugs with commercially available tool S9706 .

Removing spark plugs

657

einordnung 3. Push on the plug coils again. 4. Tighten hexagon socket heat bolts arrows to 10 Nm (7.5 ftlb.). 5. Fit shields. Reinstall the shields above the plug coils and tighten to 10 Nm (7.5 ftlb.).

6. Reinstall 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 Plug coils Shield New spark plug Old spark plug Thread M6 M6 Tightening torque Nm (ftlb.) 10 (7.5) 10 (7.5) 30 + 3 (22 + 2) 25 + 3 (18 + 2)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing spark plugs

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28 72 20 Removing and installing knock sensor Engine removed

Removing and installing knock sensor, cylinder bank 13 Removing knock sensor, cylinder bank 4 6 Installing knock sensor, cylinder bank 4 6 top of page

Removing and installing knock sensor, cylinder bank 13

Removal

1. Disconnect plug lower arrow of the knock sensor and set it aside. Unscrew M8 hexagonhead 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 sensor, always use the correct tightening torque!

3. In order to guarantee the proper function of the knock sensor, screw in the M8 hexagonhead bolt upper arrow and tighten with the correct tightening torque, then connect the plug again. Tightening torque: 23 Nm (17 ftlb.) top of page

28 72 20 Removing and installing knock sensor

Engine removed

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einordnung

Removing knock sensor, cylinder bank 4 6

1. Remove the oil container 175219 Removing and installing oil container

2. Undo the crankcase ventilation 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 aside.

5. Unscrew screw upper arrow of the knock sensor and remove the knock sensor. top of page

Removing knock sensor, cylinder bank 4 6

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einordnung

Installing knock sensor, cylinder bank 4 6

1. Clean contact surface for the sensor on the engine block. Note In order to guarantee the proper function of the knock sensor, always use the correct tightening torque!

2. Position the knock sensor, then screw in and tighten the M8 hexagonhead 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 ventilation tube. For this purpose, place the crankcase ventilation tube with the union nut arrow in position, but do not tighten yet. Note Always replace the flange seal of the crankcase ventilation tube!

Installing knock sensor, cylinder bank 4 6

661

einordnung 5. Replace the flange seal; then place the two M6 screws arrows in position and tighten. Tightening torque for hexagonhead 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, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing knock sensor, cylinder bank 4 6

662

30 01 01 Checking clutch booster circuit

Caution 1. Checking accumulator 2. Checking valve (pressureregulating valve) CAUTION Danger of material damage if the wrong fluid is used for the clutch hydraulic system! Danger of damage to property if too much Pentosin CHF 11 S is filled or if Pentosin comes into contact with the coolant hoses when topping up or filling in! Fill Pentosin CHF 11 S only into the supply tanks! To prevent overfilling and, therefore, overflowing, check the specifications in the clutch, fluid levels description and observe them without fail! Multiple steering operations (manoeuvring) and/or actuating the clutch with the engine switched off change the fluid level in the enginecompartment reservoir! Fluid 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 IMMEDIATELY! Replace visibly swollen coolant hoses!

top of page

1. Checking accumulator
1. Cold start engine (accumulator temperature approx. 20C) and let run for approx. 20 seconds (accumulator is full). 2. With the engine switched off, depress the clutch pedal repeatedly until an abrupt rise in pedal resistance against your foot can be felt (accumulator is empty). While doing this, count the number of depressions carried out up to the point of the rise in pedal pressure!

3. If the number of times the pedal was depressed is over 35, the accumulator is arrow faulty and must be replaced! => Removing and installing the accumulator top of page

2. Checking valve (pressureregulating valve)

Note 30 01 01 Checking clutch booster circuit 663

einordnung Checking the valve in the clutch save cylinder (2.1) is a direct measurement, while the valve in the upper part of expansion tank cannot be directly tested (2.2)! If there is no hydraulic clutch boost after a hold time of 24 hours, at least one of the two valves is definately damaged! Prior to the following check, ensure that the system is visually leak tight (externally)!

2.1 Checking the valve (pressureregulating valve) in the clutch save cylinder
1. Warm engine up to operating temperature (approx. 80C). Note Take care when handling Pentosin! Wear protective glasses, gloves and protective clothing! If coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY!

2. With the engine switched off and the accumulator filled (before switching off the engine, the engine must have 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 tilting, towards the tank and remove the line. 3. Collect the fluid which runs out in suitable measuring equipment (suitable container) and determine the volume of fluid collected! 4. If more than 4 cm3 is collected after a measurement period of one hour, the valve in the clutch save cylinder is faulty and and the save cylinder must be replaced. Removing and installing clutch slave cylinder => Removing and installing clutch slave cylinder.

2.2 Checking the valve (pressureregulating valve) in the upper part of the expansion tank
This valve can only be checked indirectly. A fault exists if the hydraulic clutch boost function does not last for an entire 24 hours, but where the valve in the clutch save cylinder is functioning correctly (Test 2.1).

2. Checking valve (pressureregulating valve)

664

einordnung

If the valve in the clutch save cylinder is functioning correctly according to the test in 2.1, the upper part of the tank A must be replaced. Note Before removing the upper part of the tank, slowly remove the Pentosin through the filler neck by suction! When replacing 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! Bleed clutch highpressure hydraulic system. To this purpose, depress the clutch pedal approx. 10 times!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

2.2 Checking the valve (pressureregulating valve) in the upper part of theexpansion tank

665

30 01 07 Bleeding clutch operation

Disposal of Pentosin The actuating hydraulic system is bled via pumps on the pedal. Note On righthand drive vehicles, the supply tank is located in the area of the brake fluid 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 during the procedure if necessary!

3. Pump with the clutch pedal until Pentosin emerges without air bubbles at the bleeder valve of the servo unit (use collecting bottle). Note

30 01 07 Bleeding clutch operation

666

einordnung If a bleeding device filled with Pentosin is available, clutch bleeding can proceed in the same manner as for previous systems! To do this, the bleeding device is connected to the clutch reservoir at the front! The clutch highpressure 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 system is bled in the usual manner!

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Disposal of Pentosin
Pentosin can be disposed of together with waste oil.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Disposal of Pentosin

667

30 27 19 Removing and installing clutch pressure hose Engine installed

Caution Removing clutch pressure hose Installing clutch pressure hose WARNING Danger of injury if the clutch pressure hose is undone or disconnected without pressure reduction beforehand! Reduce the pressure in the clutch system by actuating the clutch pedal at least 25 times! Note Take care when handling Pentosin! Wear protective glasses, gloves and protective clothing! Protect any coolant hoses present near to the removal work from all emerging Pentosin using suitable means! If coolant hoses come into contact with Pentosin, thoroughly clean them with water immediately!

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Removing clutch pressure hose

Requirements: Raise vehicle on lifting platform. Actuate the clutch pedal at least 25 times with the engine switched off so that the system is depressurised.

1. Unclip the plugin coupling for the hydraulic clutch operation system at the body (green line) and unscrew using two openended wrenches a/f 15 arrows A and B . 2. Collect and dispose of emerging Pentosin by suitable means. Seal the green line with suitable rubber or plastic plugs.

30 27 19 Removing and installing clutch pressure hose Engine installed

668

einordnung

3. Disconnect the clutch pressure hose 1 from the slave cylinder with an open ring or openended wrench a/f 14 and remove the hose. Note Dispose of the old hose complete with the union nut and the holder!

top of page

Installing clutch pressure hose

Note Make sure that the pressure hose is routed above the parking 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 openended wrench a/f 14.

Tightening torque 30 Nm (22 ftlb.)

2. Remove the rubber or plastic plugs from the green pressure line on the underbody and screw in a new plugin coupling (complete with union nut, holder and assembly mandrel) by hand and then screw tight with two openended wrenches a/f 15 arrows A and B . Tightening torque 30 Nm (22 ftlb.) Removing clutch pressure hose 669

einordnung 3. Then pull out the assembly mandrel and press the connecting piece of the pressure hose into the plugin coupling. Note If the pressure hose has been replaced, use a new holder and a new plugin coupling! Instructions for the plugin coupling are enclosed in the packaging! 4. Clip pressure hose back into the plastic holder. 5. Bleeding clutch operation => Bleeding clutch operation. 6. Clean residual Pentosin off the vehicle using suitable means (e.g. water).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing clutch pressure hose

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30 30 19 Removing and installing clutch slave cylinder

Removal Tightening 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 depressurised.

30 30 19 Removing and installing clutch slave cylinder

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einordnung

3. Undo the screws arrows and remove the front cross member. 4. Remove clips from the coolant lines. 5. Remove bracket for the coolant lines. 6. Remove the ventilation connection piece from the clutch housing (3 screws). Note This makes the area from the pressure line to the clutch slave cylinder more accessible! 7. Push the protection on to the left drive 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 Pentosin, thoroughly clean them with water IMMEDIATELY!

8. Remove the pressure reservoir arrow . Use an openended wrench to undo the pressure reservoir. Then turn the pressure reservoir further (remove) with an oil filter strap.

9. Disconnect (unscrew) the plug connector for the clutch hydraulic system at the body (green lead) arrow . Removal 672

einordnung

10. Remove the bracket for the slave cylinder (on transmission arrow and disconnect the slave cylinder). Only undo the slave cylinder fastening screws (2 screws) arrows slightly (do not yet unscrew completely).

11. Disconnect (unscrew) lead 1 on slave cylinder. Pull off return line 2 . To do so, press on the red ring evenly (never on one side) 2a and pull the lead out evenly while pressing (unlock). To unlock, use a commercially available removal tool. In the process, observe Workshop Equipment Manual, Chapter 2.4, No. 21 and the following note. Unscrew the pressure line 3 . Due to the restricted space, it is sensible to use a commercially available open socket wrench + adapter. Observe Workshop Equipment Manual, Chapter 2.4, No. 981. Note The tool for unlocking the return line is the tool already familiar from the 986/996. It was used there for unlocking the steering return line on the servo pump, among other elements. 12. Undo the slave cylinder fastening screws (2 screws). Carefully remove the slave cylinder. top of page

Tightening torques

Tightening Location Thread torque Nm (ftlb.) Pressure line to slave cylinder M 12 x 1 20 (15) Hose to slave cylinder M 14 x 1 30 (22) Plugin coupling for clutch hydraulic system (lead to a/f 15 30 (22) body) a/f=wrench size (across flats) Slave cylinder on transmission M10 x 35 45 (33) Bracket to slave cylinder and transmission M8 23 (17) Pressure reservoir to slave cylinder M14 x 1.5 30 (22) Tightening torques 673

einordnung Cross member at front to side section Drive shaft to transmission M10 x 1.5 M10 65 (48) 81 (60)

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Installation
Note Before installing the slave cylinder, it is sensible to remove the starter! This guarantees a better test and the unequivocal centring of the tappet push rod of the slave cylinder in the release lever! The slave cylinder can also be held in its installation position from this side! Observe the precise position of the slave cylinder before installation! The precise installation position is attained by turning in the vehicle! The loosely attached transmission slave cylinder bracket ensures the correct installation height for positioning the slave cylinder screws! 1. Remove the starter 276019 Removing and installing starter . 2. Remove the top cover (rubber cap) on the clutch housing in the area of the release 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 transmissionslave cylinder bracket loosely to the slave cylinder with a screw. It is very difficult to attach the screw later. 5. Install the clutch slave cylinder to the transmission housing/release lever. Pay attention to the correct position of the pushrod! Do not tighten the fastening screws yet. This ensures better access to the pressure line. 6. Place pressure line in position. 7. Tighten the pressure line and screw the slave cylinder tight. 8. Insert the return line. 9. Install the hose of the master cylinder line on the slave cylinder.

10. Screw the master cylinder line together arrow and insert it into the guide on the body. 11. Install the pressure reservoir. 12. Position the input shaft on the transmission flange and tighten with 81 Nm (60 ftlb.). 13. Install the bracket for the water hoses and clip the hoses into place. Align the hoses. Installation 674

einordnung 14. Install the starter 276019 Removing and installing starter. 15. Install the front cross member. 16. Connect the battery and carry out the necessary subsequent work 0 Entire Vehicle General, 0 Power supply (work instructions after connecting the battery). CAUTION Danger of material damage if the wrong fluid is used for the clutch hydraulic system! Danger of damage to property if too much Pentosin CHF 11 S is filled or if Pentosin comes into contact with the coolant hoses when topping up or filling in! Fill Pentosin CHF 11 S only into both supply tanks! To prevent overfilling and so overflowing, check the specifications in the clutch, fluid levels description and observe them without fail! Multiple steering operations (manoeuvring) and/or actuating the clutch with the engine switched off change the fluid level in the enginecompartment reservoir! Fluid 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 IMMEDIATELY! Replace visibly swollen coolant hoses! 17. Top up hydraulic fluid Pentosin CHF 11 S in the front expansion tank (luggage compartment) and in the engine compartment. Observe the prescribed procedure without fail 30 Clutch: checking fluid levels.

Pentosin tank in the engine compartment

Front Pentosin tank 18. Bleed the clutch operation (clutch hydraulic system) 30, 300107 Bleeding clutch operation.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Installation 675

30 31 19 Removing and installing the accumulator

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 Removing and installing the accumulator

676

einordnung

3. Undo the screws arrows and remove the front cross member. 4. Remove clips from the coolant lines. 5. Remove bracket for the coolant lines. Note Take care when handling Pentosin! Wear protective glasses, gloves and protective clothing! If coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY!

6. Remove the accumulator arrow . Use an openended wrench to undo the accumulator. Then turn the accumulator further (remove) with an oil filter strap. top of page

Installation
1. Set the accumulator in place and twist the accumulator into position using an oil filter strap. Use an openended 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 the hoses. 3. Install the front cross member. Tightening torque of the fastening screws: 65 Nm (48.1 ftlb.). CAUTION Danger of material damage if the wrong fluid is used for the clutch hydraulic system! Danger of damage to property if too much Pentosin CHF 11 S is filled or if it comes in contact with the coolant hoses when topping up or filling in! Fill Pentosin CHF 11 S only into the supply tanks! To prevent overfilling and, therefore, overflowing, check the specifications in the clutch, fluid levels description and observe them without fail!

Removal

677

einordnung Multiple steering operations (manoeuvring) and/or actuating the clutch with the engine switched off change the fluid level in the enginecompartment reservoir! Fluid 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 IMMEDIATELY! Replace visibly swollen coolant hoses! 4. Top up hydraulic fluid Pentosin CHF 11 S in the expansion tank in the engine compartment.

Pentosin tank in the engine compartment 5. Bleed clutch highpressure hydraulic system. To this purpose, depress the clutch pedal approx. 10 times.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

678

30 45 19 Removing and installing release bearing (clutch removed)

Removing release bearing Installing release bearing

No. Designation Qty. Removal 1 Snap ring 1 Remove using pointednose pliers, simultaneously push down pressure plate using a press. 2 Thrust plate 1

Installation Ensure correct seating

Check, do not wash out, just dry wipe

Engage lug (twist lock) in the opening of a diaphragm spring tongue Do not grease sliding surface 679

30 45 19 Removing and installing release bearing (clutch removed)

einordnung Release bearing Spring washer Spacer washer Thrust plate

4 5 6

1 2 1

Mount in correct position Fit 2 spacer washers Check for wear, replace if necessary

top of page

Removing release bearing

1. The release bearing is removed 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 freely. 2. Remove snap ring and take out release bearing. top of page

Installing release bearing

Note

Do not grease the sliding surfaces of the release bearing and the guide tube.

Removing release bearing

680

einordnung

Note

The guide sleeve of the release bearing is slotted. The slot is irregular.

1. Fit spacer washers and spring washers on the new release bearing. When doing so, ensure that 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 two tongues of the diaphragm spring. 3. Fit snap ring under the press. Ensure that the snap ring is seated correctly.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing release bearing

681

30 50 19 Removing and installing clutch

Tools Removing clutch Installing clutch Tightening torques top of page

Tools

Item A B

Designation of the special tool Toothed segment P201b Centring mandrel 9102

Explanation

top of page

Removing clutch
1. Remove transmission 34 35 27 Removing and refitting the transmission.

30 50 19 Removing and installing clutch

682

einordnung

2. Position the toothed segment P201b A on the stud and undo the panhead screws in several stages and in diametrically opposite sequence, to avoid deforming the thrust plate. top of page

Installing clutch
1. Fit drive plate with centring mandrel, special tools centring mandrel 9102 in the guide bearing (needle bush).

2. Fit thrust plate. To do so, position the special tool toothed segment P201b A on the stud and tighten the panhead screws in several stages and in diametrically opposite sequence. Tightening torque: 23 Nm (17 ftlb.) 3. Remove the special tool centring mandrel 9102 . 4. Remove the special tool toothed segment P201b . 5. Refit transmission 34 35 27 Removing and refitting the transmission. top of page

Tightening torques

Location Panhead screws thrust plate ZMS

Thread M8

Tightening torque Nm (ftlb.) 23 (17)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Removing clutch

683

30 50 37 Disassembling and assembling clutch

No. Designation 1 Panhead screw M8

Release bearing Thrust plate Drive plate Doublemass flywheel

Qty. Removal 9 In order to avoid deformation of the thrust plate housing, loosen screws in several stages and in diametrically opposite sequence. 1

Fitting In order to avoid deformation of the thrust plate housing, loosen screws in several stages and in diametrically opposite sequence. Do not wash out the bearing; replace loud bearings; do not grease the sliding surface. Centre with centring mandrel 9102 . Ensure the centring pins are seated firmly.

3 4 5

1 1 1

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

30 50 37 Disassembling and assembling clutch

684

30 56 01 Checking clutch drive plate for wear

1. Remove clutch 30 50 19 Removing and installing clutch.

2. With a depth gauge, measure the distance between the lining surface and the rivet head (dimension x). Note Only measure on the flanged side of the rivet head.

The wear dimension x measures 0.3 mm. If a smaller value 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 fashion during the service life of the clutch. Due to the settling behaviour of the clutch lining, the wear will appear to be greater at the outset. However, the wear will become less as the mileage increases.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

30 56 01 Checking clutch drive plate for wear

685

03 24 00 Minor maintenance USA

Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA Vehicles reimported from the USA must be maintained according to the maintenance schedules for RoW vehicles => Minor maintenance The maintenance schedules for the US market have been added to the Technical Manual for the sake of completeness. Note It is extremely important to check the air cleaner (and replace it if necessary) each time minor maintenance is carried out. On vehicles with annual mileages of less than 9,000 mls (15,000 km), an annual maintenance must be carried out once a year. Maintenance with oil filter change must be carried out at least every 2 years according to the mileage, if the mileage for a major maintenance has not already been reached. For an annual mileage of more than 9,000 mls (15,000 km) we recommend carrying 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 reconditioning parts or assemblies.

Minor maintenance after: OK 15,000, 45,000, 75,000, 105,000 mls etc. 24,000, 72,000, 120,000, 168,000 km etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out 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: visual inspection for completeness, installation and damage Power steering: check fluid level => Steering gear&colon; fluid level and bellows Coolant hoses: check condition Radiators and air inlets at front: visual inspection for external contamination and blockage Coolant: check the level and antifreeze protection => Checking cooling system Particle filter: replace filter element => Particle filter&colon; replacing the filter element Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level 03 24 00 Minor maintenance USA 686

einordnung => Checking and changing the brake fluid Drive shafts: visual inspection of the boots for leaks and damage => Axle joints&sol;drive shafts Tyres and spare wheel (collapsible wheel): check condition and tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and functioning properly => Checking lid and doors Vehicle lighting: check function; 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 antifreeze protection in the winter months => Windscreen wiper&sol;washer 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 lights Test drive: Remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996840, 996841

03 24 00 Minor maintenance USA

687

03 24 00 Minor maintenance as of MY 2003

Note Note Not valid for USA. The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module). On vehicles with annual mileages of less than 15,000 km (9,000 mls), an annual maintenance must be carried out once a year. Maintenance with oil filter change must be carried out at least every 2 years according to the mileage, if the mileage for a major maintenance has not already been reached. For an annual mileage of more than 15,000 km (9,000 mls) we recommend carrying 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 reconditioning parts or assemblies. 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 2003.

Minor maintenance after: OK 20,000, 60,000, 100,000, 140,000 km etc./ 12,000, 36,000, 60,000, 84,000 mls etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out 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: visual inspection for completeness, installation and damage Power steering: check fluid level => Steering gear&colon; fluid level and bellows Coolant hoses: check condition Radiators and air inlets at front: visual inspection for external contamination and blockage Coolant: check the level and antifreeze protection => Checking cooling system Particle filter: replace filter element => Particle filter&colon; replacing the filter element Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid Drive shafts: visual inspection of the boots for leaks and damage => Axle joints&sol;drive shafts Tyres and spare wheel (collapsible wheel): check condition and tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure 03 24 00 Minor maintenance as of MY 2003 688

einordnung Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and functioning properly => Checking lid and doors Vehicle lighting: check function; 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 antifreeze protection in the winter months => Windscreen wiper&sol;washer 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 lights Test drive: Remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 24 00 Minor maintenance as of MY 2003

689

03 24 00 Minor maintenance USA as of MY 2003

Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA Vehicles reimported 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 completeness. Note It is urgently recommended to check the air cleaner (and replace it if necessary) each time minor maintenace is carried out. On vehicles with annual mileages of less than 9,000 mls (15,000 km), an annual maintenance must be carried out once a year. Maintenance with oil filter change must be carried out at least every 2 years according to the mileage, if the mileage for a major maintenance has not already been reached. For an annual mileage of more than 9,000 mls (15,000 km) we recommend carrying 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 reconditioning parts or assemblies. 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 2003.

OK Minor maintenance after: 15,000, 45,000, 75,000, 105,000 mls etc. 24,000, 72,000, 120,000, 168,000 km etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out 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: visual inspection for completeness, installation and damage Power steering: check fluid level => Steering gear&colon; fluid level and bellows Coolant hoses: check condition Radiators and air inlets at front: visual inspection for external contamination and blockage Coolant: check the level and antifreeze protection => Checking cooling system 03 24 00 Minor maintenance USA as of MY 2003 690

einordnung Particle filter: replace filter element => Particle filter&colon; replacing the filter element Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid Drive shafts: visual inspection of the boots for leaks and damage => Axle joints&sol;drive shafts Tyres and spare wheel: check condition and tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and functioning properly => Checking lid and doors Vehicle lighting: check function; 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 antifreeze protection in the winter months => Windscreen wiper&sol;washer 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 lights Test drive: Remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996840, 996841

03 24 00 Minor maintenance USA as of MY 2003

691

03 24 00 Minor maintenance as of MY 2004

Note Note Not valid for USA. The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module). There is no annual maintenance for vehicles as of model year 2004. If the mileage for a regular service is not reached, minor maintenance must be carried out after 2, 6, 10..... years. 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 assemblies. 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 2003.

Minor maintenance after: OK 20,000, 60,000, 100,000, 140,000 km etc./ 12,000, 36,000, 60,000, 84,000 mls etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out 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: visual inspection for completeness, installation and damage Power steering: check fluid level => Steering gear&colon; fluid level and bellows Coolant hoses: check condition Radiators and air inlets at front: visual inspection for external contamination and blockage Coolant: check the level and antifreeze protection => Checking cooling system Particle filter: replace filter element => Particle filter&colon; replacing the filter element Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid Drive shafts: visual inspection of the boots for leaks and damage => Axle joints&sol;drive shafts Tyres and spare wheel (collapsible wheel): check condition and tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and functioning properly => Checking lid and doors Vehicle lighting: check function; all headlights: check adjustment; horn: check operation => Checking the function of the vehicle's lights 03 24 00 Minor maintenance as of MY 2004 692

einordnung Windscreen 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 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, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 24 00 Minor maintenance as of MY 2004

693

03 24 00 Minor maintenance USA as of MY 2004

Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA Vehicles reimported 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 completeness. Note It is urgently recommended to check the air cleaner (and replace it if necessary) each time minor maintenace is carried out. There is no annual maintenance for vehicles as of model year 2004. If the mileage for a regular service is not reached, minor maintenance must be carried out after 2, 6, 10..... years. 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 assemblies. 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 2003.

OK Minor maintenance after: 15,000, 45,000, 75,000, 105,000 mls etc. 24,000, 72,000, 120,000, 168,000 km etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out 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: visual inspection for completeness, installation and damage Power steering: check fluid level => Steering gear&colon; fluid level and bellows Coolant hoses: check condition Radiators and air inlets at front: visual inspection for external contamination and blockage Coolant: check the level and antifreeze protection => Checking cooling system Particle filter: replace filter element => Particle filter&colon; replacing the filter element Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid 03 24 00 Minor maintenance USA as of MY 2004 694

einordnung Drive shafts: visual inspection of the boots for leaks and damage => Axle joints&sol;drive shafts Tyres and spare wheel (collapsible wheel): check condition and tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure Check the door locks, lid locks and safety hooks of the front lid to ensure that they are secure and functioning properly => Checking lid and doors Vehicle lighting: check function; 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 antifreeze protection in the winter months => Windscreen wiper&sol;washer 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 lights Test drive: Remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 24 00 Minor maintenance USA as of MY 2004

695

32 47 19 Removing and installing torqueconverter sealing ring

Tools Removing the torqueconverter sealing ring Installing the torqueconverter sealing ring top of page

Tools

Item A B

Designation of the special tool Lever VW 681 Pressure piece 9670

Explanation

top of page

Removing the torqueconverter sealing ring

Removing converter 32 Removing and installing torque converter .

32 47 19 Removing and installing torqueconverter sealing ring

696

einordnung 1. Lever out the sealing ring using the lever VW 681 . top of page

Installing the torqueconverter 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, 996621, 996650, 996651

Removing the torqueconverter sealing ring

697

32 50 19 Removing and installing torque converter

Tools Removing the torque converter Installing the torque converter top of page

Tools

Item

Designation of the special tool Locating pin 9595/1

Explanation long

top of page

Removing the torque converter

1. Remove enginetransmission unit ( 100119 ) and remove the transmission ( => Removing and refitting the transmission).

2. With transmission in horizontal position, remove the converter. Use two M8 x 120 screws for this purpose. 32 50 19 Removing and installing torque converter 698

einordnung top of page

Installing the torque converter

Note Check converter hub for traces of scoring. In the event of damage or faults, the converter must be replaced. 1. Carefully push converter onto transmission shaft as far as the first stop. Then press converter by hand into the converter bell housing and turn it until the 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 installed position of the converter is incorrect, the ATF pump can be destroyed when the transmission is flangemounted to the engine.

3. Fix converter in installation position with special tool (locating pin) 9595/1 .

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Removing the torque converter

699

03 26 00 Major maintenance USA

Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA Vehicles reimported 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 completeness. Note 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 assemblies. The maintenance item > Throttle actuation: Check smooth operation, check full throttle position with the Tester < omitted as of model year 2002.

Major maintenance after OK 30,000, 60,000, 90,000, 120,000 mls etc. 48,000, 96,000, 144,000, 192,000 km etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out fault memory 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 and engine compartment: visual inspection for leaks (oils and fluids) and abrasion (lines and hoses) Underbody 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: check the level and antifreeze protection => Checking cooling system Air cleaner: replace filter element => Replacing air cleaner element Particle filter: replace filter element => Particle filter&colon; replacing the filter element Fuel system: visual inspection for damage, routing and secure fit of line connections Power steering: check fluid level => Steering gear&colon; fluid level and bellows Parking brake: check the free play of the parking brake lever => Parking brake&colon; checking the free play of the parking brake lever Brake system: visual inspection of the brake pads and brake discs for wear => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs

03 26 00 Major maintenance USA

700

einordnung Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid Clutch: play or pedal end position is to be checked => Clutch&colon; checking the play and pedal end position Throttle actuation: check smooth operation, check the full throttle position with the Tester Steering gear: visually inspect the bellows for damage => Steering gear&colon; fluid level and bellows Tie rod ends: checking the play and dust bellows => Axle joints&sol;drive shafts Axle joints: check play, visual inspection of dust bellows for damage => Axle joints&sol;drive shafts, check screw connections of running gear adjustment facility, front and rear, for secure fit => Running gear adjustment&sol;storage of assemblies Drive shafts: visual inspection of the boots 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 => 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 secure 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 => Checking the function of the vehicle's lights Windscreen 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 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, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996840, 996841

03 26 00 Major maintenance USA

701

03 26 00 Major maintenance as of MY 2003

Note Note Not valid for USA. The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module). 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 assemblies. The maintenance item > Throttle actuation: Check smooth operation, check full throttle position with the Tester < omitted 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 2003.

Major maintenance after OK 40,000, 80,000, 120,000, 160,000 km etc./ 24,000, 48,000, 72,000, 96,000 mls, etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out fault memory 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 and engine compartment: visual inspection for leaks (oils and fluids) and abrasion (lines and hoses) Underbody 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: check the level and antifreeze protection => Checking cooling system Air cleaner: replace filter element => Replacing air cleaner element Particle filter: replace filter element => Particle filter&colon; replacing the filter element Fuel system: visual inspection for damage, routing and secure fit of line connections Power steering: check fluid level => Steering gear&colon; fluid level and bellows Parking brake: check the free play of the parking brake lever => Parking brake&colon; checking the free play of the parking brake lever Brake system: visual inspection of the brake pads and brake discs for wear => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid 03 26 00 Major maintenance as of MY 2003 702

einordnung Clutch: play or pedal end position is to be checked => Clutch&colon; checking the play and pedal end position Steering gear: visually inspect the bellows for damage => Steering gear&colon; fluid level and bellows Checking the tie rod end play and dust bellows => Axle joints&sol;drive shafts Axle joints: check play, visual inspection of dust bellows for damage => Axle joints&sol;drive shafts, check screw connections of running gear adjustment facility, front and rear, for secure fit => Running gear adjustment&sol;storage of assemblies Drive shafts: visual inspection of the boots 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 => 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 secure 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 => Checking the function of the vehicle's lights Windscreen 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 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, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996840, 996841

03 26 00 Major maintenance as of MY 2003

703

03 26 00 Major maintenance USA as of MY 2003

Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA Vehicles reimported 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 completeness. Note 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 assemblies. The maintenance item > Throttle actuation: Check smooth operation, check full throttle position with the Tester < omitted 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 2003.

Major maintenance after OK 30,000, 60,000, 90,000, 120,000 mls etc. 48,000, 96,000, 144,000, 192,000 km etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out fault memory 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 and engine compartment: visual inspection for leaks (oils and fluids) and abrasion (lines and hoses) Underbody 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: check the level and antifreeze protection => Checking cooling system Air cleaner: replace filter element => Replacing air cleaner element Particle filter: replace filter element => Particle filter&colon; replacing the filter element Fuel system: visual inspection for damage, routing and secure fit of line connections Power steering: check fluid level => Steering gear&colon; fluid level and bellows Parking brake: check the free play of the parking brake lever => Parking brake&colon; checking the free play of the parking brake lever

03 26 00 Major maintenance USA as of MY 2003

704

einordnung Brake system: visual inspection of the brake pads and brake discs for wear => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid Clutch: play or pedal end position is to be checked => Clutch&colon; checking the play and pedal end position Throttle actuation: check smooth operation, check the full throttle position with the Tester Steering gear: visually inspect the bellows for damage => Steering gear&colon; fluid level and bellows Tie rod ends: check the play and dust bellows => Axle joints&sol;drive shafts Axle joints: check play, visual inspection of dust bellows for damage => Axle joints&sol;drive shafts, check screw connections of running gear adjustment facility, front and rear, for secure fit => Running gear adjustment&sol;storage of assemblies Drive shafts: visual inspection of the boots 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 => 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 secure 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 => Checking the function of the vehicle's lights Windscreen 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 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, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996840, 996841

03 26 00 Major maintenance USA as of MY 2003

705

03 26 00 Major maintenance as of MY 2004

Note Note Not valid for USA. The engine oil and oil filter must be changed every 10,000 km (6,000 mls) on vehicles which are operated in countries where the fuel has a high sulphur content (country coding M 150 in the control module). There is no annual maintenance for vehicles as of model year 2004. If the mileage for a regular service is not reached, major maintenance must be carried out after 4, 8, 12..... years. 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 assemblies. The maintenance item > Throttle actuation: Check smooth operation, check full throttle position with the Tester < omitted 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 2003.

Major maintenance after OK 40,000, 80,000, 120,000, 160,000 km etc./ 24,000, 48,000, 72,000, 96,000 mls, etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out fault memory 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 and engine compartment: visual inspection for leaks (oils and fluids) and abrasion (lines and hoses) Underbody 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: check the level and antifreeze protection => Checking cooling system Air cleaner: replace filter element => Replacing air cleaner element Particle filter: replace filter element => Particle filter&colon; replacing the filter element Fuel system: visual inspection for damage, routing and secure fit of line connections Power steering: check fluid level => Steering gear&colon; fluid level and bellows Parking brake: check the free play of the parking brake lever => Parking brake&colon; checking the free play of the parking brake lever

03 26 00 Major maintenance as of MY 2004

706

einordnung Brake system: visual inspection of the brake pads and brake discs for wear => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid Clutch: play or pedal end position is to be checked => Clutch&colon; checking the play and pedal end position Steering gear: visually inspect the bellows for damage => Steering gear&colon; fluid level and bellows Tie rod ends: check the play and dust bellows => Axle joints&sol;drive shafts Axle joints: check play, visual inspection of dust bellows for damage => Axle joints&sol;drive shafts, check screw connections of running gear adjustment facility, front and rear, for secure fit => Running gear adjustment&sol;storage of assemblies Drive shafts: visual inspection of the boots 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 => 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 secure 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 => Checking the function of the vehicle's lights Windscreen 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 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, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 26 00 Major maintenance as of MY 2004

707

03 26 00 Major maintenance USA as of MY 2004

Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA Vehicles reimported 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 completeness. Note There is no annual maintenance for vehicles as of model year 2004. If the mileage for a regular service is not reached, major maintenance must be carried out after 4, 8, 12..... years. 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 assemblies. The maintenance item > Throttle actuation: Check smooth operation, check full throttle position with the Tester < omitted 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 2003.

OK Major maintenance after 30,000, 60,000, 90,000, 120,000 mls etc. 48,000, 96,000, 144,000, 192,000 km etc. Diagnostic system: read out fault memory => Diagnostic system&colon; reading out fault memory 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 and engine compartment: visual inspection for leaks (oils and fluids) and abrasion (lines and hoses) Underbody 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: check the level and antifreeze protection => Checking cooling system Air cleaner: replace filter element => Replacing air cleaner element Particle filter: replace filter element => Particle filter&colon; replacing the filter element 03 26 00 Major maintenance USA as of MY 2004 708

einordnung Fuel system: visual inspection for damage, routing and secure fit of line connections Power steering: check fluid level => Steering gear&colon; fluid level and bellows Parking brake: check the free play of the parking brake lever => Parking brake&colon; checking the free play of the parking brake lever Brake system: visual inspection of the brake pads and brake discs for wear => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid Clutch: play or pedal end position is to be checked => Clutch&colon; checking the play and pedal end position Steering gear: visually inspect the bellows for damage => Steering gear&colon; fluid level and bellows Tie rod ends: check the play and dust bellows => Axle joints&sol;drive shafts Axle joints: check play, visual inspection of dust bellows for damage => Axle joints&sol;drive shafts, check screw connections of running gear adjustment facility, front and rear, for secure fit => Running gear adjustment&sol;storage of assemblies Drive shafts: visual inspection of the boots 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 => 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 secure 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 => Checking the function of the vehicle's lights Windscreen 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 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, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 26 00 Major maintenance USA as of MY 2004

709

34 01 55 Changing transmission oil

Changing transmission oil Tightening torques top of page

Changing transmission oil

Note Top up only with transmission oil approved by Porsche. See Parts Catalogue! Filling capacity: 3.8 litres Change quantity: 3.0 litres 1. Place oil collection pan under the transmission.

2. Unscrew the oil filler screw 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 bottom edge of the oil filler opening. 6. Tighten filler plug to 30 Nm (22 ftlb.). top of page

Tightening torques

Location Filler plug for transmission oil Drain plug for transmission oil

Thread M22 M22

Tightening torque Nm (ftlb.) 30 (22) 30 (22)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

34 01 55 Changing transmission oil

710

34 08 19 Removing and installing shift console

Tools Removing and installing shift console Removing shift console Installing shift console Tightening torques top of page

Tools

Item 1

Designation of the special tool Locking bridge 9619

Explanation

top of page

Removing and installing shift console

34 08 19 Removing and installing shift console

711

einordnung

A B C D

Shift console Selector cable (blue) Shift cable (black) Shift console cover

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. Remove shift console cover.

Removing and installing shift console

712

einordnung

4. Disengage selector cable A and shift cable B on shift console. To do this, slide the locking sleeve F forward as far as it will go and turn it clockwise to removal position. A Selector cable (blue) B Shift cable (black) C Adjuster open D Adjuster closed E Support bracket sleeve F Locking sleeve 5. Carefully disengage support bracket sleeves E upward out 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 console

Note The shifting element is designed so that installation and adjustment are a single work step. Precondition: Special tool (locking bridge) 9619 must be fitted to fix the shift lever. The transmission must be in neutral. 1. Insert the shift console and tighten the fastening nuts. Tightening torque: 10 Nm (7.5 ftlb.)

Removing shift console

713

einordnung

2. Insert the support brackets E in the correct position in the shift console. It must be possible to hear and feel the support brackets engage. A Selector cable (blue) B Shift cable (black) C Adjuster open D Adjuster closed E Support bracket sleeve 3. Engage the shift cable B and selector cable A in the open adjusters C 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 test. 5. Clip in shift console cover. 6. Install centre console 68 17 19 Removing and installing centre console. top of page

Tightening torques

Location Shift console fastening screws

Thread M6

Tightening torque Nm (ftlb.) 10 (7.5)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing shift console

714

34 12 19 Removing and installing shift and selector cables

Tools Removing and installing shift and selector cables Tightening torques top of page

Tools

Item Designation of the special Explanation tool A Removal tool Commercially available (refer to Workshop Equipment Manual, Chapter 2.4, No. 21) B Locking bridge 9619

top of page

Removing and installing shift and selector cables

34 12 19 Removing and installing shift and selector cables

715

einordnung

A Selector cable (blue) B Shift cable (black) C Rubber sleeve

Removing shift and selector cables

Note The shift and selector cables have a common rubber sleeve 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 position and fix with special tool (locking bridge) 9619 . 3. Remove shift console cover.

Removing and installing shift and selector cables

716

einordnung Overview of shift console A Selector cable (blue) B Shift cable (black) C Adjuster open E Adjuster closed E Support bracket sleeve F Locking sleeve 4. Disengage selector cable A and shift cable B on shift console. To do this, slide the locking sleeve F forward as far as it will go and turn it clockwise to removal position. 5. Carefully disengage support bracket sleeves E upward out of the shift console. Unlock 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 shift cable end pieces B on the transmission lever. 9. Detach the support bracket sleeves A at the support bracket. To do this, unclip the support bracket sleeve (see enlarged view) and pull it out of the support bracket.

10. Remove transmission support.

11. Bend up the tabs A in the vehicle interior at the body opening and press the rubber sleeve outward

Removing shift and selector cables

717

einordnung through the body opening. 12. Press the shift and selector cables downward through the body opening. To do this, carefully press the support bracket sleeves through the body opening and pull the B+ wire out of the slotted rubber sleeve.

Installing shift and selector cables

Note Each time the shift cables are removed from the transmission lever, the retaining clips of the shift cable end pieces must be replaced. 1. Apply a generous coating of lubricant (e.g. Contifix tyre mounting paste) on the rubber sleeve and B+ wire in the area of the body opening.

2. Push shift 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 support bracket. 5. Fasten shift cable end pieces on the shift lever. 6. Install transmission support. Tightening torque: 65 Nm (48 ftlb.) 7. Fit underbody panels (middle and rear). 8. Bend tabs in the vehicle interior downward so that the rubber sleeve can no longer slip out of place. 9. Install parking brake console. Tightening torque: 23 Nm (17 ftlb.) 10. Check function of parking brake and adjust it if necessary. 46 83 16 Adjusting parking brake shoes. Note The shift and selector cables are routed underneath the console.

Installing shift and selector cables

718

einordnung

11. Insert the support brackets E in the shift console. It must be possible to hear and feel the support brackets engage. A Selector cable (blue) B Shift cable (black) C Adjuster open E Adjuster closed E Support bracket sleeve 12. Engage the shift cable B and selector cable A in the open adjusters C and close the adjusters (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 console cover. 15. Install centre console. 68 17 19 Removing and installing centre console. top of page

Tightening torques

Location Parking brake console Transmission support

Thread M8 M10

Tightening torque Nm (ftlb.) 23 (17) 65 (48)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

719

34 35 27 Removing and refitting the transmission

Tools Removing transmission Refitting transmission Tightening torques top of page

Tools

Item Designation of the special tool Gripper

Explanation Commercially available Workshop Equipment Manual Chapter 2.4, No. 50

top of page

Removing transmission
1. Remove enginetransmission unit 100119 . 2. Disengage starter cable on the right air flange.

34 35 27 Removing and refitting the transmission

720

einordnung

3. Undo pressure pipe from slave cylinder.

4. Unscrew fastening screws for slave cylinder. 5. Hang slave cylinder on the engine without tension.

6. Remove left air flange and unscrew hexagonhead 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 pull out shaft. 9. Unscrew the fastening nuts for engine/transmission and separate the transmission from the engine. top of page

Removing transmission

721

einordnung

Refitting transmission
Refitting occurs in reverse order, observing the following points: Note Grease teeth of the drive shaft with a very thin coat of Olista Longtime 3P (only as protection against corrosion).

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 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. Refitting transmission 722

einordnung 1 Hexagonhead bolt 2 Holder 3 Bearing cover 4 Needleroller bearing with assembly bore 5 Sealing ring 6 Clutch control shaft 7 Release lever 5. Remove adhesive tape through the assembly opening in the release fork. 6. Fit needleroller bearing, bearing cover and support for clutch control shaft. top of page

Tightening torques

Location Transmission on engine Air flanges on transmission Slave cylinder on transmission Bracket for slave cylinder on transmission Bracket for clutch control shaft on transmission

Thread M10 M6 M10 x 35 M8 x 20 M6 x 16

Tightening torque Nm (ftlb.) 45 (33) 10 (7.5) 45 (33) 23 (17) 10 (7.5)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

723

34 49 19 Removing and installing closure cap for selector force mechanism

Tools Removing and installing closure cap for selector force mechanism Tightening torques top of page

Tools

Item 1

Designation of the special tool Pressout mandrel P 375

Explanation

top of page

Removing and installing closure cap for selector force mechanism

34 49 19 Removing and installing closure cap for selector force mechanism

724

einordnung

A Closure cap

Removing closure cap for selector force mechanism

1. Remove enginetransmission unit. 10 01 19 Removing and installing engine.

2. Shift transmission to neutral, unscrew fastening screw A and 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 transmission). Screw in a sheetmetal screw (4.8 x 25) with a large washer and lever out the closure cap using two screwdrivers.

Removing and installing closure cap for selector forcemechanism

725

einordnung

Installing closure cap for selector force mechanism

1. Insert closure cap and snap ring into the housing bore. 2. Use special tool (pressout mandrel) P 375 to push the snap ring and closure cap down until the snap ring engages in its groove. Note Ensure perfect seating of the snap ring. 3. Tighten fastening screw for gear housing. Tightening torque: 25 Nm (19 ftlb.) 4. Install enginetransmission unit. 10 01 19 Removing and installing engine. top of page

Tightening torques

Location Gear housing on transmission housing

Thread M8

Tightening torque Nm (ftlb.) 25 (19)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing closure cap for selector force mechanism

726

03 50 00 Annual maintenance USA

Caution WARNING Damage is possible if the wrong maintenance schedules are used for reimported vehicles! These maintenance schedules are invalid for RoW (rest of world) vehicles and for vehicles reimported from the USA Vehicles reimported 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 completeness. Note On vehicles with annual mileages of less than 9,000 mls (15,000 km), an annual maintenance must be carried out once a year. Regular servicing with oil filter change must be carried out at least every 2 years according to the mileage, if the mileage for a major maintenance has not already been reached. For an annual mileage of more than 9,000 mls (15,000 km) we recommend carrying out the next regular servicing 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 assemblies.

Annual maintenance OK Diagnostic system: read out fault memory => Diagnostic system&colon; reading out fault memory Vehicle underside 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 inlets at front: visual inspection for external contamination and blockage => Checking cooling system Power steering: check fluid level => Steering gear&colon; fluid level and bellows Engine: check oil level => Changing the engine oil and oil filter Brake hoses and lines: visual inspection for damage, routing and corrosion => Visual inspection&colon; brake lines&sol;brake pads&sol;brake discs. Check brake fluid level => Checking and changing the brake fluid Steering gear: visually inspect the bellows for damage => Steering gear&colon; fluid level and bellows Tie rod ends: check the play and dust bellows => Axle joints&sol;drive shafts Axle joints: check the play and visually inspect the dust bellows for damage => Axle joints&sol;drive shafts 03 50 00 Annual maintenance USA 727

einordnung Drive shafts: visual inspection of the boots for leaks and damage => Axle joints&sol;drive shafts Tyres and spare wheel (collapsible wheel): check condition and tyre pressure => Tyres and spare wheel&colon; checking condition and tyre pressure Vehicle lighting: check function; all headlights: check adjustment; horn: check operation => Checking the function of the vehicle's lights 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 lights Test drive: Remote control, front seats, foot and parking brakes (also actuation travel), engine, clutch, steering, transmission, ParkAssist, automatic speed control, PSM switch, heating, airconditioning system and instruments: check operation => General maintenance&colon; test drive Oils, fluids: visual inspection for leaks

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

03 50 00 Annual maintenance USA

728

03 50 00 Annual maintenance 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 as of MY 2004

729

03 50 00 Annual maintenance USA as of MY 2004

The maintenance schedules for 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, 996650, 996651, 996840, 996841

03 50 00 Annual maintenance USA as of MY 2004

730

37 02 35 Checking and topping up the ATF

Tools Checking and topping up the ATF Tightening torques top of page

Tools

Item

Special tool designation Connection hose 9507/1

Remarks

top of page

Checking and topping up the ATF

Note Top up only with ATF approved by Porsche. See Parts Catalogue!

37 02 35 Checking and topping up the ATF

731

einordnung

Note

The stipulated fluid level is extremely important for perfect functioning of the automatic transmission. It is correct if there is a slight amount of ATF escaping at the control screw bore B at temperatures between 30 C and 40 C. Testing conditions: The transmission must not be in the reduced driving program. The ATF temperature must be between 30 C and 40 C. An ATF inspection at an insufficient ATF temperature causes overfilling and an inspection at an excessive ATF temperature causes insufficient filling. Selector lever in position "P" and engine idling. The airconditioning 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 Tester 2 and call up the ATF temperature. Note The ATF temperature must not be higher than 40 C at the start of the test. 3. Move selector lever to position "P" and allow engine to idle. WARNING Danger of injury from emerging ATF fluid! ATF fluid can cause burns and chemical burns to the eyes! Wear protective goggles

4. Unscrew control screw B . If ATF escapes from the control bore and if the ATF temperature is 30 C to 40 C, the ATF level is in order. If there is enough ATF fluid in the transmission, then Checking and topping up the ATF 732

einordnung continue with step 10. Note The control screw must be closed no later than when an ATF temperature of 45 C is reached. 5. If no ATF escapes from the control bore even though approx. 40 C has been reached, the ATF must be topped up. Note To undo and tighten the cap nut for the charging valve, counter with an openended wrench. 6. Screw off cap nut for the charging valve.

7. 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 charging valve. Tightening torque: 40 Nm (30 ftlb.) 10. Screw in ATF control screw with a new sealing ring. Tightening torque: 22 Nm (16 ftlb.) top of page

Tightening torques

Location Control screw to ATF pan Cap nut to charging valve

Thread M10 M14 x 1.5

Tightening torque Nm (ftlb.) 22 (16) 40 (30)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

733

37 02 55 Replacing ATF fluid

Tools Replacing ATF fluid Tightening torques top of page

Tools

Item

Special tool designation Connection hose 9507/1

Remarks

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: approx. 4.5 litres 1. Place oil collection pan under the transmission.

37 02 55 Replacing ATF fluid

734

einordnung

2. Unscrew drain plug A and drain ATF. Note Without ATF, the engine must not be started and the vehicle must not be towed. 3. Replace sealing ring for drain plug and screw in plug. Tightening torque: 22 Nm (16 ftlb.)

4. Unscrew control screw B . Note To undo and tighten the cap nut for the charging valve, counter with an openended 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 the charging valve until surplus ATF runs out at the control screw bore. Note All instructions and test conditions for "Checking and topping up ATF fluid" must be observed for further work steps (see Serv. No. 370235).

Replacing ATF fluid

735

einordnung 7. Connect the Porsche System Tester 2 and call up the ATF temperature. 8. Move selector lever to position "P" and allow engine to idle.

9. With engine running, top up ATF again until excess ATF emerges from the bore of the ATF control screw B . 10. With the brake pedal pressed, change through all selector lever positions, remaining in each position for approx. 10 s. Note The ATF temperature must not be higher 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 ftlb.) 13. Screw in the ATF control screw with a new sealing ring and tighten it to 20 Nm (15 ftlb.). Tightening torque: 22 Nm (16 ftlb.) top of page

Tightening torques

Location Drain plug to ATF pan Control screw to ATF pan Cap nut to charging valve

Thread M10 M10 M14 x 1.5

Tightening torque Nm (ftlb.) 22 (16) 22 (16) 40 (30)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

736

37 08 19 Removing and installing selector support

Removing and installing selector support Tightening torques top of page

Removing and installing selector support

Removing selector support

1. Remove selector knob 37 04 19 Removing and installing selector knob. 2. Remove centre console 68 17 19 Removing and installing centre console. 3. Press together the retaining clip on the 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 sleeve E forward as far as it will go and turn it clockwise to removal position (see enlarged view 2). 6. Carefully disengage support bracket sleeve F upward out of the selector support. Unlock the support bracket sleeves by pressing in both plastic clips (see enlarged view 3). 7. Unscrew fastening nuts G for selector support.

37 08 19 Removing and installing selector support

737

einordnung

8. Disconnect electrical plug connections A and remove the selector support.

Installing selector support

Note Install in reverse order to removal. 1. Insert selector support and connect electrical plug connections. 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 engage properly. (See enlarged view).

4. Push selector lever cable all the way back (see enlarged view); this shifts the transmission into park. 5. Move selector lever to position P.

Removing selector support

738

einordnung

6. 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 position automatically. 7. Engage cable nipple in the keylock lever. 8. Insert adjuster on the keylock 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 Removing and installing selector knob. top of page

Tightening torques

Location Shift console fastening screws

Thread M6

Tightening torque Nm (ftlb.) 10 (7.5)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing selector support

739

37 15 19 Removing and installing selector lever cable

Tools Removing and installing selector lever cable Tightening torques top of page

Tools

Item Designation of the special Explanation tool 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 knob 37 04 19 Removing and installing selector knob. 2. Remove centre console 68 17 19 Removing and installing centre console.

37 15 19 Removing and installing selector lever cable

740

einordnung

3. Disengage selector lever cable A on the selector support. To do this, slide the locking sleeve B forward as far as it will go and turn it clockwise to removal position (see enlarged 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 parking brake console. 6. Remove underbody panels (middle and rear).

7. Remove transmission support.

8. Remove plastic cover A around pinion shaft.

Removing selector support

741

einordnung

9. Remove transmission lever A from the transmission housing. To do this remove retaining clamp D from the pivot point. Undo the transmission lever holder screws C and remove the transmission lever holder B .

10. Remove support bracket sleeve A on selector lever cable from support bracket B . To do this, press retaining clip C together 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 selector lever cable can be pulled down somewhat with the transmission lever to allow better access to the separation point. Note When separating the selector lever cable and the transmission lever, make sure not to bend the transmission lever or kink the selector lever cable too much.

Removing selector support

742

einordnung 12. Bend up the tabs A in the vehicle interior at the body opening and press the rubber sleeve outward through the body opening. 13. Pull B+ cable out of the slotted sleeve and pull the selector lever cable out through the body opening.

Installing selector support

Note Install in reverse order to removal. 1. Apply a generous coating of lubricant (e.g. Contifix tyre mounting paste) on the rubber sleeve and B+ wire in the area of the body opening.

2. Push selector cable 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. Press end piece of the selector lever cable onto the ball head on the transmission lever. 5. Insert support bracket sleeve on the selector lever cable into the support bracket. Ensure correct seating of retaining clip in the support bracket. 6. Fit transmission lever and transmission lever holder. Ensure that the retaining clamp is seated correctly.

Tightening torque for holder screws: 23 Nm (17 ftlb.) 7. Fit plastic cover around pinion shaft. 8. Install transmission support. Tightening torque: 65 Nm (48 ftlb.) 9. Install underbody panels (middle and rear). 10. Install parking brake console. Tightening torque: 23 Nm (17 ftlb.) Installing selector support 743

einordnung 11. Check function of parking brake and adjust if necessary. 46 83 16 Adjusting parking brake shoes.

12. Insert support bracket sleeve on the selector lever cable in the support bracket on the selector support. Make sure the two plastic clips engage properly. (See enlarged view)

13. Push selector lever cable all the way back (see enlarged view); this shifts the transmission into 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 position automatically. 16. Install centre console. 68 17 19 Removing and installing centre console. 17. Install selector knob. 37 04 19 Removing and installing selector knob. top of page

Tightening torques

Location Parking brake console Transmission support Transmission holder

Thread M8 M10 M8

Tightening torque Nm (ftlb.) 23 (17) 65 (48) 23 (17)

Tightening torques

744

einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

745

37 35 27 Removing and refitting the transmission

Note Tools Removing transmission Refitting transmission Tightening torques Note When installing a new 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

Tools

Item A B

Special tool designation Holder 9674 Locating pin 9595/1

Remarks long

top of page

37 35 27 Removing and refitting the transmission

746

einordnung

Removing transmission
1. Remove enginetransmission unit 100119 . 2. Remove starter 276019 . 3. Disengage B+ wire on bracket. 4. Pull off vacuum line for flatseat 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 converter fastening screws through the starter opening in the converter housing. Note Removing transmission 747

einordnung Turn the crankshaft 120 further in each case for the remaining four fastening screws. 10. Unscrew the remaining four fastening screws.

11. Remove crash support.

12. Unscrew the two upper fastening screws of the converter bell housing and suspend the transmission from the workshop crane with 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 holding the converter. 14. Remove transmission with converter. top of page

Refitting transmission
Refitting occurs in reverse order, observing the following points:

1. Push special tool additional support 9111/6 all the way into the engine retainer plate.

Refitting transmission

748

einordnung

2. Check installation dimension of the converter. Installation dimension approx. 15 mm

3. Hold converter in installation position with special tool locating pin 9595/1 and push transmission in until the toothed ring on the flywheel touches the centering pin. 4. Remove special tool locating pin 9595/1 , push the transmission 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 support 9111/6 . top of page

Tightening torques

Location Torque converter to driver plate Crash support to intermediate case Transmission to intermediate case

Thread M8x20 M8x60 M8x35

Tightening torque Nm (ftlb.) 39 (29) 23 (17) 23 (17)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

749

37 58 19 Removing and installing ATF filter

Tools Removing ATF filter Installing ATF filter Tightening torques top of page

Tools

Item

Special tool designation Connection hose 9507/1

Remarks

top of page

Removing ATF filter

1. Remove underbody panels, rear and centre.

2. Remove cross member. 37 58 19 Removing and installing ATF filter 750

einordnung 3. Disengage cable at the retaining clips of the ATF pan. 4. Place oil collection pan under the transmission.

5. Unscrew drain plug A and drain ATF. Note Without ATF, the engine must not be started and the vehicle must not be towed. 6. Remove ATF pan (loosen screws crosswise).

7. Remove ATF filter. top of page

Installing ATF filter

1. Thinly 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 torque: 8 Nm (6 ftlb.) 4. Replace sealing ring for ATF drain plug and tighten screw. Tightening torque: 22 Nm (16 ftlb.) 5. Fill in ATF. => Checking and topping up the ATF 6. Engage cable on the retaining clips of the ATF pan. 7. Install cross member. Tightening torque: 65 Nm (48 ftlb.) 8. Install rear underside panel. top of page Removing ATF filter 751

einordnung

Tightening torques

Location Drain plug to ATF pan ATF pan to transmission Transmission cross member to body

Thread M 10 M6 M 10

Tightening torque Nm (ftlb.) 22 (16) 8 (6) 65 (48)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

752

38 77 19 Removing and installing electrohydraulic control unit

Tools Removing the electrohydraulic control unit Installing the electrohydraulic control unit Tightening torques top of page

Tools

Item A B C

Special tool designation Assembly aid 9663 Ratchet 1/4 inch Extension 1/4 inch

Remarks Commercially available Commercially available

top of page

Removing the electrohydraulic control unit

38 77 19 Removing and installing electrohydraulic control unit

753

einordnung

Note Do not let engine run with the ATF pan removed 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.

Removing the electrohydraulic control unit

754

einordnung

5. Disengage the coolant hoses in the area of the flanged shaft. 6. Pull vacuum pipe off the switchover valve. 7. Undo the left drive flange on the transmission 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 assembly aid 9663 and pull out the bushing. 11. Place oil collection pan under the transmission.

Removing the electrohydraulic control unit

755

einordnung

12. Unscrew drain plug A and drain ATF. 13. Remove ATF pan (loosen screws crosswise).

14. Remove ATF filter.

15. Place selector lever in position P and unscrew the fastening screws for the control unit. top of page

Installing 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 valve must engage in the driver of the notched plate. 2. First tighten screws for the control unit hand tight. Then tighten. Tightening torque: 8 Nm (6 ftlb.). Installing the electrohydraulic control unit 756

einordnung 3. Replace gasket for ATF pan.

4. Insert the plug connection with new sealing rings in the correct position and tighten the fastening screw. Tightening torque: 2.5 Nm (2 ftlb.). 5. Screw in ATF drain plug. Tightening torque: 22 Nm (16 ftlb.).

6. Push the plug 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. Tightening torque: 10 Nm (7.5 ftlb.).

8. Install the coolant hoses with hose holders in the correct position. 9. Push vacuum pipe onto switchover valve. 10. Fill in ATF. => Checking and topping up the ATF

Installing the electrohydraulic control unit

757

einordnung top of page

Tightening torques

Location Cross member to carrier side section Plug connection to socket Drain plug to ATF pan Control screw to ATF pan ATF pan to transmission Control unit to transmission Water hose holder to transmission

Thread M10 M4 M10 M10 M6 M6 M6

Tightening torque Nm (ftlb.) 65 (48) 2.5 (2.0) 22 (16) 22 (16) 8 (6) 8 (6) 10 (7.5)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

758

38 77 37 Disassembling and assembling electrohydraulic control unit

Tools Overview Disconnecting hydraulic and electrical control unit Removing solenoid and control valve Installing solenoid and control valve Reassembling the hydraulic and electrical control unit top of page

Tools

Item Special tool designation Gripper

Remarks Commercially available (refer to Workshop Equipment Manual, Chapter 2.4, No. 50)

top of page

Overview

38 77 37 Disassembling and assembling electrohydraulic control unit

759

einordnung

No. 1 2 3 4 5 6 7 8 9 10 11 12

Designation Cover Cover Screw (6x80) Screw (6x55) Leaf spring Solenoid valve, 23 gearshift Control solenoid valve, converter jumper Solenoid valve, 12 and 45 Solenoid valve, 34 gearshift Control solenoid valve, shifting pressure Control solenoid valve, modulating pressure Electrical control unit

Qty. 1 1 2 1 3 1 1 1 1 1 1 1

Removal

Installation

Tighten to 8 Nm (6 ftlb.) Tighten to 8 Nm (6 ftlb.) Mount in correct position Pull out with gripper As No. 6 As No. 6 As No. 6 As No. 6 As No. 6

Overview

760

einordnung 13 Hydraulic control unit 1

top of page

Disconnecting hydraulic and electrical control unit

1. Remove electrical control unit 12 in overview . To do so, bend back the retaining lug at the strengthening rib on the oil temperature sensor. top of page

Removing solenoid and control valve

1. Pull off plastic cover 1 or 2 in overview. 2. 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 valve

1. Press in new magnet or control valve 6 to 11 in overview . Ensure correct seating. 2. Fit leaf spring 5 in overview and screw in screw 3 in overview . 3. Fit plastic cover 1 or 2 in overview . top of page

Reassembling the hydraulic and electrical control unit

Disconnecting hydraulic and electrical control unit

761

einordnung 1. Place the control unit 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

Reassembling the hydraulic and electrical control unit

762

40 41 19 Removing and installing the front drive shaft

Tools Removal Installation top of page

Tools

Item Designation of the special tool A Torx screwdriver 9546

Explanation To counter the ball joints (track rod and joint mount) during assembly and disassembly.

Ball joint extractor (track rod extractor), commercially available; refer to Workshop Equipment Manual, Chapter 2.4, No. 113 Pressout tool (ball joint extractor) 9560 To press out the ball joint on the wheel carrier.

top of page

Removal
Note Before raising the vehicle, undo the drive shaft fastening at the wheel side! Actuate the brake while doing this!

40 41 19 Removing and installing the front drive shaft

763

einordnung Remove diagonal brace to facilitate assembly (2 M12 screws)! 1. Remove front wheel and underside panel. 2. Undo the panhead screws of the drive shaft on the transmission flange. Note The CV joint can come apart if the dust bellows holder arrow is removed or damaged. The joint must therefore be secured against falling apart during removal, installation and transport with 8 mm screws + nuts (2 ea.)!

When loosening the fastening nuts, counter with special tool 9546 (Torx screwdriver)! 3. Disengage air guide on control arm. 4. Loosen stabilizer mount at stabilizer (counter with openended wrench). 5. Undo track rod and control arm on wheel carrier.

6. Press ball joint off control arm 1 with pressout tool 9560 and ball joint off track rod 2 using a commercially available track rod extractor. Note To prevent damage to the rubber sleeves of the ball joints, coat the rubber sleeves and the extractors in this area with tyre mounting paste! Since the drive shaft can be moved in the wheel hub toothing only with great use of force, undo the drive shaft using a copper mandrel (driving mandrel)! For unfavourable tolerances, the drive shaft must be pressed out of the wheel hub toothing using a suitable wheel hub extractor! 7. Push protective tube (shopmade) onto the drive shaft (profile shaft). 8. Swivel (pull) spring strut outwards without using excess force and extend drive shaft. Removal 764

einordnung 9. Do not damage the boots of the ball joints. Push a transport protective cap onto the joint if necessary. top of page

Installation
Install in reverse order. Note Before installing, give the parts a visual check! Replace fastening nuts! Use correct tightening torques! Grease the toothing of the drive shaft with Optimoly HT! Additionally, only on the front axle, grease the 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 drive shaft with Optimoly HT. 2. Swivel spring strut outwards and insert drive shaft into the vehicle. 3. Insert panhead screws with shim plates into the halfshaft flange. 4. Insert drive shaft and fit panhead screws. Fit new fastening nut M22 x 1.5. 5. Fit ball joints on wheel carrier.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

765

40 85 19 Removing and installing front spring strut

Removal Installation

Item Designation of the special tool Explanation A Torx screwdriver 9546 To counter the ball joints (track rod and joint mount) during assembly and disassembly. B Ball joint extractor (track rod Commercially available; refer to Workshop Equipment Manual, extractor) Chapter 2.4, No. 113. C Pressout tool (ball joint To press out the ball joint on the wheel carrier. extractor) 9560

top of page

Removal
1. Open front lid and remove the respective cover (right or left). 2. Undo nut from drive shaft, raise vehicle and unbolt wheel. 3. Disengage air guide on control arm. 4. Loosen stabilizer mount at stabilizer (counter with openended wrench). 5. Undo track rod and control arm on wheel carrier.

40 85 19 Removing and installing front spring strut

766

einordnung

Note

Use pressout tool 9560 C to press off the control arm 1 ! Use a commercially available track rod extractor to press off the track rod 2 ! When loosening the fastening nut, counter with Torx screwdriver! 6. Open plug connection on wheel carrier. Pull out the plugs and disconnect the plug connections on the spring strut. 7. Loosen holder for brake lines/brake hose at wheel carrier. 8. Loosen brake caliper from wheel carrier and attach in wheel arch. 9. Mark the position 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 frontaxle final drive! 10. Loosen clamped connection between spring strut and wheel carrier and pull out spring strut from wheel carrier. top of page

Installation
Install in reverse order to removal. Note Before installing, give the parts a visual check! Do not grease screwed connections in Dacromet finish Use correct tightening torques! 1. Replace brake caliper fastening screws and selflocking nuts. 2. Insert the drive shaft into the toothing of the wheel hub. aluminium colour!

Removal

767

einordnung

Note

The installation side "RE" (right) or "LI" (left) arrow is stamped on the spring strut mount! Note the installed position of the spring strut mount! The arrow markings must 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 replaced that affect the vehicle height, a complete wheel alignment is necessary!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

768

42 58 19 Removing and installing rearwheel bearing

Tools Notes on removal and installation top of page

Tools

Designation of the special Item tool A Pressout mandrel P 297 a B Separator (12115 mm ) C Tubular piece VW 415A D Pressure piece 9247

Explanation For pressing out the rearwheel hub

Commercially available, see Workshop Equipment Manual, Chapter 2.4, No. 111. As a support when pressing out the rearwheel hub and the wheel bearing inner race of the wheel hub For pressing the wheel bearing out and in Use in combination with tubular pieceC to press in the wheel bearing

Removing and installing rearwheel bearing

42 58 19 Removing and installing rearwheel bearing

769

einordnung

No. Designation 1 Wheel hub

Qty. Removal 1 Press out with pressure piece P 297 a under a hydraulic press. For this purpose, use the separator and corresponding shims for support. 4 1 1

2 3 4

Hexagonhead bolt (10.9) Lid Wheel bearing

Installation Press in under a hydraulic press. To do this, place the wheel hub on the wheel centring device and press it on the wheel bearing inner race using pressure piece VW 415 A. Tighten to 37 Nm (27 ftlb.)

Fit in correct position (groove down). Insert new wheel bearing in correct Heat wheel bearing housing to position (inscription facing the wheel approx. 100 C (max. 120 C). hub), and then press again slightly using Press out wheel bearing with tubular piece VW 415 A (tool C). pressure piece 9247/3 (tool D) and tubular piece VW 415 A (tool C).

top of page

Notes on removal and installation

Note The wheel bearing is removed and installed with the wheel bearing housing removed.

Removing and installing rearwheel bearing

770

einordnung

Removal
1. Remove brake disc, parking brake shoes, brake disc cover and speed sensor.

2. Press the rearwheel hub out using pressout mandrel P 297 a . Use the separator as a support. If there is not enough space for the wheel hub between the press, 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 (tool C ).

Note

Pull the inner bearing race several millimetres off the wheel hub so that the separator can be put into place. For this purpose, use a twoclaw puller in combination with a suitable pressure piece (e.g. VW 433).

Removal

771

einordnung 5. Press inner wheel bearing race off the wheel hub. Use the pressout mandrel P 297 a in connection with the separator.

Installation
1. Before installation, clean the bore in the wheel bearing housing and remove any surface irregularities with a polishing cloth.

2. Heat wheel bearing housing to approx. 100 C (max. 120 C). Insert new wheel bearing, 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 correct position i.e. facing downward. Observe tightening torque: 37 Nm (27 ftlb.)

4. Press in wheel hub. To do this, place the wheel hub on the wheel centring device and press it on the wheel bearing inner race using pressure piece VW 415 A (tool C).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

772

42 71 19 Removing and installing rear spring strut

Removal Installation top of page

Removal
1. Lift the vehicle. 2. Remove the rear wheel.

3. Mark the installed position of the spring strut mount (position of the three collar nuts, arrows ). 4. Loosen fastening nuts M10 from the spring strut mount in the vehicle interior. 5. Loosen stabilizer mount at stabilizer (counter with openended wrench).

6. Loosen screw connection between spring strut/wheel carrier arrow . 7. Pull out (remove) spring strut. top of page

Installation
Install in reverse order. Note Before installing, give the parts a visual check! Replace fastening nuts! Do not grease screwed connections in Dacromet finish Use correct tightening torques! aluminium colour!

42 71 19 Removing and installing rear spring strut

773

einordnung When new parts are installed that affect vehicle height, suspension alignment must be carried 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 (34 ftlb.).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

774

44 05 19 Removing and installing the wheel Turbo and GT2

Wheel mounting Turbo and GT2 Removing/installing the wheel on vehicle Turbo and GT2 top of page

Wheel mounting Turbo and GT2

The wheels of the Turbo and GT2 are mounted with series wheel bolts A M14 x 1.5 (length 45 mm) dimension X ! The intially planned procedure of using GT3 wheel bolts B M14 x 1.5 (length 50 mm) dimension X is not applicable! Previous written publications should be altered accordingly!

Wheel bolts A 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 GT2

Note Use suitable commercially available tools (wrench size 19 mm)! Never use an impact bolter to tighten the wheel bolts! Before the wheel is placed on the wheel hub, regrease the centering surface of the wheel hub (if required) as necessary with a very thin coat of Optimoly TA (aluminium paste)! The wheel bolt consists of two parts that are permanently joined together! Other wheel bolts must not be used! CAUTION

44 05 19 Removing and installing the wheel Turbo and GT2

775

einordnung Vehicles with PCCB (Porsche Ceramic Composite Brake): Danger of material damage during wheel removal/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) are located in the luggage compartment!

1. In the case of vehicles with PCCB (Porsche Ceramic Composite Brake), screw the 2 assembly aids (assembly pins), instead of 2 wheel bolts, into the wheel hub before wheel removal/installation. During removal, first 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 wheels with series wheel bolts (Turbo and GT2) A M14 x 1.5 (length 45 mm) dimension X . 3. In the case of heavy soiling, clean the wheel bolts and the concavities in the wheel with a lintfree cloth.

4. Always apply a thin coat of Optimoly TA (aluminium paste) on the thread of the wheel bolts, on the shank and between the bolt head bearing surface and spherical cap ring (under the head) arrows . Do not grease the spherical cap bearing surface X of the wheel bolts that faces the wheel. Removing/installing the wheel on vehicle Turbo and GT2 776

einordnung A Spherical cap ring (permanently connected with the wheel bolt) X Spherical cap bearing surface facing the wheel (do not grease) Note Rework on wheel bolts is impermissible! 5. Always replace damaged wheel bolts. This damage includes mechanical damage to the thread, the spherical cap and damage 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 Always observe the specified tightening torque of 130 Nm (96 ftlb.)! 6. Screw in wheel bolts by hand and then tighten evenly. Start at the top when tightening.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing/installing the wheel on vehicle Turbo and GT2

777

44 35 19 Removing and installing valve (steel valve) (Turbo ll wheel)

General Notes on removal and installation Removal Installation top of page

General
The steel valve must always be replaced when changing a tyre! CAUTION Loss of tyre pressure if the installation position of the components is not observed and the original Porsche SP parts are not used when installing the steel valve. Fix disc into the correct position using the Oring and the fastening nut! Only use the original valve cap!

top of page

Notes on removal and installation

Do not use commercially available steel valves. The Porsche valves (part nos. 993.361.073.00) are shorter (dimension X). Dimension X is approx. 43 mm for the Porsche version! The complete valve only is available as a spare part. See Spare Parts catalogue! The valve insert is commercially available!

44 35 19 Removing and installing valve (steel valve) (Turbo ll wheel)

778

einordnung The valve cap 1 is provided with a seal (airtight seal). Do not confuse with a commercially available valve cap! The shaft of the fastening nut 2 must point towards the valve foot, because otherwise the valve will not be secure!

Position of the disc must be observed 3 arrow . If the disc is fitted incorrectly, the Oring 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 in the valve foot. There is a slit in the valve foot to aid countering. Remove disc 3 and Oring 4 . Pull out valve 5 . top of page

Installation

1. Insert valve 5 with the fitted foot seal (6) into the wheel. The foot seal 6 is always fitted with new valves! Notes on removal and installation 779

einordnung

2. Place Oring 4 carefully on to the valve from the outside. Mount disc 3 in the correct position arrow . The Oring then lies in the 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 with a screwdriver on the slot of the valve foot.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

780

45 11 19 Removing and installing front speed sensors

Removal Installation top of page

Removal
1. With ignition switched off, open the combination plug connection at the spring strut and pull out the plug for the speed sensor. 2. Loosen fastening screw (hexagon socket head bolt) and remove the speed sensor. top of page

Installation
Note Before installation, ensure that there are no metal chips at the magnetic edge of the speed sensor! The gap between speed sensor and pulse wheel is determined by the design and cannot be adjusted! There is no Oring 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 Longterm 2. 2. Without using excessive force, insert speed sensor into wheel carrier and tighten the hexagon socket head bolt to 10 Nm (7.5 ftlb.). 3. If the speed sensor has been removed or replaced due to an ABS fault or Traction Contol fault, or because of accident repairs, a functional check should be carried out with the Porsche System Tester 2 via the Actual Values menu, Speed submenu.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

45 11 19 Removing and installing front speed sensors

781

45 15 19 Removing and installing rear speed sensors

Removal Installation top of page

Removal
1. With ignition switched off, open the combination plug connection at the spring strut and pull out the plug for the speed sensor.

2. Loosen fastening screw (hexagon socket head bolt) and remove the speed sensor. top of page

Installation
Note Before installation, ensure that there are no metal chips at the magnetic edge of the speed sensor! The gap between speed sensor and pulse wheel is determined by the design and cannot be adjusted! There is no Oring 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 Longterm 2. 2. Without using excessive force, insert speed sensor into wheel carrier and tighten the hexagon socket head bolt to 10 Nm (7.5 ftlb.). 3. If the speed sensor has been removed or replaced due to an ABS fault or Traction Contol fault, or because of accident repairs, a functional check should be carried out with the Porsche System Tester 2 via the Actual Values menu, Speed submenu.

45 15 19 Removing and installing rear speed sensors

782

einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

783

45 30 19 Removing and installing hydraulic unit

Replacing the hydraulic unit Removal Installation top of page

Replacing the hydraulic unit

When replacing the hydraulic unit D , observe the following points! 3 hydraulic unit variants have been installed in the 911 Turbo (996) since the production launch. First version 996.355.955.51, modified version 996.355.955.57 and new/current version 996.355.955.58. The first version 996.355.955.51 is no longer available since existing supplies have been used up. Instead of the first version 996.355.955.51, the 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 that the combination hydraulic unit/rateofturn sensor is correct! This means: the hydraulic unit 996.355.955.58 can only be combined with the new/current rateofturn sensor (part number 996.606.145.00). Replace the rateofturn sensor if necessary. For the conversion of the firstversion rateofturn sensor (part number 996.606.147.00) to the new/current version (part number 996.606.145.00), see 455931 Conversion of rateofturn sensor.

First version: Rateofturn sensor with part No. 996.606.147.00

45 30 19 Removing and installing hydraulic unit

784

einordnung

New/current version: Rateofturn sensor with part No. 996.606.145.00.

top of page

Removal

Note

For the removal and installation of the hydraulic 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 pedal with pedal holder , so that the brake fluid does not run out of the expansion tank completely.

Replacing the hydraulic unit

785

einordnung

3. To remove the hydraulic unit D , carry out the following removal procedure: Undo the brake lines on the hydraulic unit. Remove the lines between the brake master cylinder intermediate piston circuit and the hydraulic unit. Close the brake lines and the brake line connections with suitable plugs. Pull off pressure sensor plug. Unlock/disconnect the control module plug on the hydraulic unit. Cover the plug connector and the plug! Note In the case of assembly work on the hydraulic 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 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 and may cause faults in the system! Undo and guide out the hydraulic unit. In the case of unfavourable tolerances, remove the hydraulic unit without the bracket for the hydraulic unit. top of page

Installation
1. Install in reverse order. Note First connect the electrical plug connections on the hydraulic unit, so that the plug connections inside or on the hydraulic unit can not be splashed with brake fluid or water! After bleeding, check the assignment of the brake lines/solenoid valves to the correct brake calipers! To do so, call up the PSM system with the PST 2 and carry out a swap test! 2. Bleed the brakes => Bleeding brakes (vehicle with PSM). Note Removal 786

einordnung First bleed brakes as usual! Do not carry out booster pump activation with the Porsche System Tester 2 until after this has been done (after conventional bleeding) as otherwise damage to the booster pump can occur! To bleed at front on right with running booster pump, the bleeding device should remain connected (switched on)! Bleeding pressure approximately 2.0 bar! 3. When replacing the hydraulic unit, code the control module (manual transmission/Tiptronic). 4. Carry out the following tests: Check the system (brake lines and 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 hydraulic lines (brake lines) for incorrect assignment using the PST 2. Then start the engine. The PSMrelated lights in the instrument cluster must go out when the engine is running. Carry out a function check of the brakes. Then perform a short test drive and perform at least one ABS control operation, taking the road conditions into consideration. Read out the PSM fault memory again. There must not be any stored faults.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

787

45 59 19 Removing and installing rateofturn sensor

Removal Installation Two versions of the rateofturn sensor have been installed for the PSM (Porsche 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 996.606.145.00.

Note The transverse acceleration sensor is integrated in the rateofturn sensor.

45 59 19 Removing and installing rateofturn sensor

788

einordnung

First version of the rateofturn sensor with part number 996.606.147.00. will no longer be available after existing supplies are used up.

The new/current rateofturn sensor 996.606.145.00 (introduction shortly before the end of model year 2000) can be retrofitted instead of the first version 996.606.147.00. In case of firsttime 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 "Conversion of rateofturn sensor" => Conversion of rateofturn sensor.

top of page

Removal
CAUTION The rateofturn sensor is a micromechanical component and is very sensitive to impacts! Note Perform removal and installation with the ignition switched off! 1. Move the front seats into the rear seat position.

Removal

789

einordnung

2. Remove sidepanel lining in front of the centre console on the left A and right.

3. Remove fastening nuts of the rateofturn sensor on the right arrow and left. 4. Pull out the rateofturn sensor and unlock and pull off the plug with the ignition switched off. Note Pull at the plug housing only! Never pull the electrical connections!

top of page

Installation
1. Install in reverse order.

2. After installing the rateofturn sensor, read out the PSM fault memory with the Porsche System Tester 2 and erase. Carry out a static test. Then start the engine. The PSMrelated lights in the instrument cluster must go out when the engine is running. Read out the PSM fault memory again. There must not be any stored faults.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

790

45 59 31 Conversion of rateofturn sensor

Overview of rateofturn sensor conversion Removal Fitting Two versions of the rateofturn sensor have been installed 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 with part number 996.606.145.00.

Note The transverse acceleration sensor is integrated in the rateofturn sensor.

45 59 31 Conversion of rateofturn sensor

791

einordnung

First version: Rateofturn sensor with part No. 996.606.147.00 After supplies of the old sensor have been used up, install the new rateofturn sensor with part number 996.606.145.00!

New/current version: Rateofturn sensor with part No. 996.606.145.00. Introduced in production shortly prior to the end of model year 2000. The new/current rateofturn sensor can be retrofitted. The following instructions describe the conversion. top of page

Overview of rateofturn sensor conversion

In case of firsttime installation of the new/current rateofturn sensor, the front centre console support 1 and the holder 2 must be replaced. The following parts are omitted: The bow 4 over the rateofturn sensor 3 and the cable guide 5 . The adapter plug X must be installed between the plug 6 and the rateofturn sensor 3 .

Overview of rateofturn sensor conversion

792

einordnung

Front centre console support Holder Rateofturn sensor Bow over rateofturn sensor Cable guide Plug (Item X = adapter plug that is installed between the new rateofturn sensor and the existing plug). The table below for the 911 Turbo (996) provides an overview of the part allocation for replacement of a rateofturn sensor 996.606.147.00 (first version). Component SP No. / explanation PSM control 996.618.149.01 module (Installed as standard) Hydraulic unit 996.355.955.51 (Installed as standard) Rateofturn 996.606.145.00 sensor (Item 3) Adapter plug 996.622.901.00 (Item X) The adapter plug (adapter lead) is installed between the new rateofturn sensor and the existing plug Holder (Item 2) 996.552.309.08 Front centre 996.552.267.05 console support (Item 3) Bow over the 996.606.143.00 rateofturn Omitted sensor (Item 4) Cable guide (Item 996.610.224.00 5) Omitted

1 2 3 4 5 6

Overview of rateofturn sensor conversion

793

einordnung Note The adapter plug is necessary because the plug and the connector assignment have changed as well!

top of page

Removal
CAUTION Danger of damage! The negative terminal of the battery must be disconnected before the airbag control unit is removed! Never disconnect battery with engine running! Never start engine without securely connected battery! Never use a boost charger 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 seat position. 2. Disconnect the ground wire of the battery and cover the terminal or battery.

3. Remove sidepanel lining in front of the centre console on the left A and right.

4. Remove centre console front part B 681719 Removing and installing centre console (front part). Then remove centre console C 681719 Removing and installing centre console.

Removal

794

einordnung

5. Remove cable guide for the rateofturn sensor and remove the front centre console support arrows .

6. On Tiptronic vehicles, disengage (loosen) the keylock cable 5 on the selector lever: To do this Press the retaining clip 4 together and carefully pull the adjuster 3 upward out of the support bracket. Disengage cable nipple 1 on the keylock lever 2 .

7. Unlock plug of the rateofturn sensor with the ignition switched off arrow on the plug and pull it off. Undo fastening nuts arrows and remove the rateofturn sensor with bow. Note Pull at the plug housing only! Never pull the electrical connections!

8. Remove the airbag control module 695319 Removing and installing triggering unit for the airbag. Removal 795

einordnung

Note

Socket wrench insert 9259 is required for removal and installation of the airbag triggering unit.

9. Undo the fastening screws arrows on both sides and remove the holder 2 . To do this, guide the electrical wiring and, if necessary, the keylock cable through the holder opening. top of page

Fitting
CAUTION The rateofturn sensor is a micromechanical 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 approx. 110 mm. To do this, guide the electrical wiring and, if necessary, the keylock cable through the holder opening. Fit the plastic clips and the clips from the old holder on the new holder. 2. Install airbag control unit. Use new shearoff nuts. Tightening torque of the M6 hexagon nut: 10 Nm (7.5 ftlb.)

Fitting

796

einordnung

3. On Tiptronic vehicles, engage (fasten) the keylock cable on the selector lever. To do this, engage the cable nipple 1 on the keylock lever 2 . Press housing for adjuster 3 into the support bracket until the retaining clip 4 engages. Note The new rateofturn sensor has a different plug and a different connector assignment. For this reason, it is necessary to fit an adapter plug (adapter lead with plugs) between the new rateofturn sensor and the existing plug! 4. Install the adapter plug (adapter lead with plugs) and the rateofturn sensor. To do this:

Connect the plug on the adapter lead X to the existing plug 6 . Then secure this plug connection firmly to the red lead A with a tiewrap B so that it can not slip.

Fit rateofturn sensor (new/current version) 3 part no. 999.606.145.00. First, feed (route) the adapter lead X under the rateofturn sensor 3 . Then connect the plug arrow on the adapter lead X to the rateofturn sensor 3 . Note There is no bow over the new rateofturn sensor!

Fitting

797

einordnung

5. Prepare new/current support B (with dimension X = approx. 8 mm) for installation. Distinguishing characteristics: Dimension X and diameter of the hole arrows . Dimension X of the holder for the first version A approx. 12 mm.

6. Install new/current support B .

7. Install centre console C 681719 Removing and installing centre console. Then install centre console front part B 681719 Removing and installing centre 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 memories of the airbag, PCM and PSM control modules with the Porsche System Tester 2. Additionally perform the static test in the PSM system. Then start the engine. The PSMrelated lights in the instrument cluster must go out when the engine is running. Read out the PSM fault memory again. There must not be any stored faults.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Fitting

798

45 60 19 Removing and installing steering angle sensor

Notes on steering wheel position during removal and installation Removal Notes on replacing the steering angle sensor vehicles prior to '03 model Installation

A steering angle sensor C is attached to the steering column/steering shaft for PSM (Porsche Stability Management) in the 911 Turbo. Cover D remains fitted during removal and installation of the steering angle sensor. Removal of cover D is generally not permitted. A C D Universal joint of steering shaft Steering angle sensor. Modified versions as of 2003 model => Notes on replacing the steering angle sensor vehicles prior to '03 model Cover

top of page

Notes on steering wheel position during removal and installation

Lock the steering wheel and the front wheels in a straightahead position. Make sure that this position is retained for reinstallation. Refit in the same position during installation. If this is not done, the airbag contact unit (spiral spring) can be damaged. Also, the steering wheel can be crooked when the front wheels are in a straightahead position after the steering angle sensor has been installed.

top of page

Removal
1. Remove driver's seat. 2. Switch ignition off.

45 60 19 Removing and installing steering angle sensor

799

einordnung

3. Remove air duct. 4. Turn front wheels to a straightahead position. Fix the front wheels and the steering wheel in this position.

5. Undo hexagonhead bolt on universal joint A . Detach universal joint A from the upper steering shaft and push into the lower steering shaft (direction arrow ). Disengage cable guide 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 steering angle sensor plug. The plug can be pulled off to the side direction arrow or to the front (depending on the design of the steering angle sensor). Disengage steering angle sensor C to the front. To do this, press carefully on the sensor (direction arrow ) through the opening in cover D . Removal 800

einordnung top of page

Notes on replacing the steering angle sensor vehicles prior to '03 model

A new steering angle sensor C2 is installed as of the 2003 model (3programme). This internally modified steering angle sensor, C2 , differs (externally) from the previous steering angle sensor, C1 , in having a larger plug connection that is also located in a different position. New steering angle sensor C2 : 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 the previous version, C1 .

When new steering angle sensor C2 is installed in vehicles prior to the 2003 model, new cable guide B2 (instead of the previous cable guide) and adapter lead E must be installed because of the modified plug connection (larger plug, position of plug and modified plug assignment).

Notes on replacing the steering angle sensor vehicles prior to '03 model

801

einordnung

The main difference between the old cable guide, B1 , and the new cable guide, B2 , (implemented as standard as of the 2003 model) is the cable deflector at the end of the cable. There are interruptions (openings) in the cable slot (ribs) of new cable guide B2 for routing the lead (there is no open circuit in 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 with the plug connection into the cable slot of new cable guide B2 and secured with a tiewrap arrow . Note Before inserting leads E and X into the cable slot, fold them so that the leads lie directly above one another and are correctly positioned.

Component overview

Component overview

802

einordnung Designation New component Steering 996.606.119.00 angle sensor (C2 = new sensor) Cable guide 996.610.123.01 (B2 = new cable guide) Adapter lead 996.622.906.00 E Replaced component 996.606.109.02

996.610.123.00

Additional lead (connection between the old lead and the new steering angle sensor)

Pin assignment of adapter lead E Small plug Large plug (connection to the (connection to the plug from the old new steering steering angle angle sensor) sensor) Pin 1 Ground Pin 4 Pin 2 + 12 V Pin 3 (vehicle voltage) Pin 3 CAN H Pin 2 Pin 4 CAN L Pin 1

top of page

Installation
CAUTION The airbag will not function if the spiral spring in the airbag contact unit is 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 shaft). This means that if the steering wheel is turned to fit the steering angle sensor, the same steering wheel position, and thereby the position of the spiral spring in the airbag contact unit, must be reestablished before fitting the universal joint. The front wheels, steering wheel and airbag contact unit must be positioned correctly in relation to one another before the universal joint is fitted on the upper steering shaft, i.e. they must be in the same positions that they were in before the removal (the steering wheel and spiral spring are positioned centrally and the wheels are in a straightahead position). Note

Installation

803

einordnung The steering angle sensor and its hub adapter must engage audibly. Use a new fastening screw on the universal joint. Observe the tightening torque of the screw. When replacing the steering angle sensor in pre2003 vehicles, ensure that the components in the surrounding areas are correctly assigned (this is determined by the steering angle sensor version that is used). The steering angle sensor has no defined zero position when new. The position for "straight ahead" direction of travel must be programmed. This is done by calibrating with the Porsche System Tester, when the wheels are in a straightahead position, on the measuring station.

1. Secure the steering angle sensor to the steering column (steering shaft) in 2 stages . Stage 1: Secure (engage) 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 locking tab (for securing to the upper steering shaft) 4 External locking tab 5 Engagement (cutout) on the driver Detailed instructions: First, disengage hub adapter1 from driver 2 of the steering angle sensor engagement 5 and pull it out.

Push hub adapter 1 onto the steering shaft. Locking tabs 3 and 4 must be facing the steering wheel. Internal locking tab 3 must engage completely in the cutout in drive shaft 6 . Check that it is fitting securely: hub adapter 1 must not be able to twist on the steering shaft. In order for the cutout in steering shaft 6 to be visible in the opening of cover D , twist the steering wheel out of its original position beforehand. Then return the steering wheel to its original position.

Installation

804

einordnung

Push steering angle sensor C across the hub adapter that has already been fitted. The driver of steering angle sensor 2 is facing the steering column. External locking tab 4 in the hub adapter must engage completely in the driver engagement. In order for locking tab 4 to be visible in the opening of cover D , twist the steering wheel out of its original position beforehand. Then return the steering wheel to its original position. Note If the steering wheel was not secured before the steering wheel sensor was removed or if the steering wheel was twisted when the steering angle sensor was 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 steering shaft (universal joint) A in correct position the same position that it was in before the removal (wheels are in a straightahead position, steering wheel and spiral spring are in a central position) to the upper steering shaft. 3. Push plug onto steering angle sensor (plug in cable) and engage cable guide B . Install the new cable guide with the adapter lead only when modified steering angle sensor version C2 is used for the first time in vehicles prior to the 2003 model (see following text).

Conversion new steering angle sensor in vehicles prior to the 2003 model

Installation

805

einordnung When converting from the old to the new steering angle sensor design, C2 , new cable guide B2 and new adapter lead E (large plug on steering angle sensor) must be installed instead of the old cable guide and previous lead (small plug on steering angle sensor). To do this: Fit new cable guide B2 (engage on the steering column) and insert adapter lead E . Plug in (engage) the large plug on adapter lead E to new steering angle sensor C2 . Join together the plug from existing lead X and the plug from adapter lead E . Insert existing lead X and adapter lead E , together with the plug connection, into the cable slot and secure with a thin tiewrap arrow . Before inserting the leads into the cable slot, fold them so that the leads lie directly above one another and are correctly positioned.

4. Install air duct. CAUTION Malfunctions in the PSM control range if the steering angle sensor is not calibrated or is calibrated incorrectly. The steering angle sensor has no defined zero position when new. The position for "straight ahead" direction of travel must be programmed. Calibrate steering angle sensor using the Porsche System Tester with the wheels in a straightahead position on the measuring station. 5. Calibrating steering angle sensor => Steering angle sensor.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

806

45 64 19 Remove and install booster pump for PSM

Removal Installation top of page

Removal

Note

The booster pump 1 is removed with the holder 1a . 1. Switch off ignition.

2. Remove cover A from the hydraulic unit.

3. For the removal of the booster pump, 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 arrows and disconnect. Remove connector housing rearwards from out of the bracket moving arrow . Undo the three plastic fastening nuts 5 and remove the booster pump 1 with the holder 1a . top of page 45 64 19 Remove and install booster pump for PSM 807

einordnung

Installation
1. Install in reverse order. 2. Bleed the brakes 47 01 07 . Note First bleed brakes as usual! Do not carry out booster pump activation with the Porsche System Tester 2 until after this has been done (after conventional bleeding) as otherwise damage to the booster pump can occur! To bleed at front on right with running booster 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 module with the Porsche System Tester 2. Carry out a static test. Then start the engine. The PSMrelated lights in the instrument cluster must go out when the engine is running. Read out the PSM fault memory again. There must not be any stored faults.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

808

46 11 15 Adjusting the brake pushrod

The brake pedal has no stop. Since, when the brake pushrod is correctly set, the brake pedal has no support possibility in its original position, the permanently set free play in the brake unit is guaranteed. As a result a pushrod play of approx. 1 mm is noticeable by manual actuation on 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 and turn the pushrod accordingly at the hexagon arrow .

Brake pushrod

The brake pushrod is correctly set if dimension X = 45 + 5 mm. Perform measurement between the centre of the brake pedal plate and the accelerator.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

46 11 15 Adjusting the brake pushrod

809

46 36 20 Removing and installing the front disc brake pads

Caution Removal Installation WARNING Danger of accident if brake pads with the wrong brake pad quality are installed! Use only the typespecific brake pads in the Porsche Spare Parts Catalogue! The pad backing plates (rear side of the brake pads) must not be greased! Replace vibration 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 (safety bracket) arrow and extract the retainer pin inwards. 2. Pull out the warning contact wire on the brake caliper and remove the warning contacts from the brake pad plates. 3. Pull out the warning contact wire on the brake caliper and remove the warning contacts from the

46 36 20 Removing and installing the front disc brake pads

810

einordnung brake pad plates. Note Replace warning contacts if the core of the wire is worn or worn through! The warning contact can continue to be 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 the container!)! 4. Remove brake pads with a brake pad puller. Always observe the following important points! Set back the brake pads as far as possible with the piston resetting fixture (press back)! Pull out brake pads together with the vibration dampers! If this is not possible (depending on wear of the brake pads), use a spatula to detach the vibration dampers from the brake pad backing plate before removing the pads!

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Installation
WARNING Danger of accident if old parts are fitted on 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 backing plates (rear side of the brake pads) must not be greased! 1. Before installation of the brake pads, check the wear of the brake discs. For minimum thickness of the brake discs, see Technical data/Brake wear limit in Repair Group 46. 2. If necessary, turn back the piston to its original position using the resetting fixture. 3. Fit new vibration dampers in the pistons. Remove protective film from the vibration dampers before installation. 4. Insert the brake pads.

Removal

811

einordnung

5. Fit new expanding spring, new retaining pin and new retainer (safety bracket) arrow . These parts are available as a repair set and must be renewed each time the pads are changed. 6. Insert the warning contact wire and warning contacts. 7. Firmly press the brake pedal several 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 beddingin period of approx. 200 km! Not until then do they achieve their best friction and wear coefficient. During this period, the brakes should be subjected to full stress when travelling at high speed only in emergencies.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

812

46 38 20 Removing and installing the rear disc brake pads

Caution Removal Installation WARNING Danger of accident if brake pads with the wrong brake pad quality are installed! Use only the typespecific brake pads in the Porsche Spare Parts Catalogue! The pad backing plates (rear side of the brake pads) must not be greased. Replace vibration dampers 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 bracket) arrow and extract the retainer pin inwards. 2. Pull out the warning contact wire on the brake caliper and remove the warning contacts from the brake pad plates. 3. Pull out the warning contact wire on the brake caliper and remove the warning contacts from the brake pad plates.

46 38 20 Removing and installing the rear disc brake pads

813

einordnung Note Replace warning contacts if the core of the wire is worn or worn through. The warning contact can continue to be used if there are only scrape marks on the plastic part of the warning contact. 4. Remove brake pads with a brake pad puller. Always observe the following important points! Note If necessary, remove some brake fluid by suction from the brake fluid reservoir beforehand (brake fluid may escape over the rim of the container!). Set back the brake pads as far as possible with the piston resetting fixture (press back). Pull out brake pads together with the damper plates. If this is not possible (depending on wear of the brake pads), use a spatula 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 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 backing plates (rear side of the brake pads) must not be greased. 1. Before installation of the brake pads, check the wear of the brake discs. For minimum thickness of the brake discs, see Technical data/Brake wear limit in Repair Group 46. 2. If necessary, turn back the piston to its original position using the resetting fixture. 3. Fit new damper plates in the pistons. Remove protective film from the damper plates before installation. 4. Insert the brake pads.

Removal

814

einordnung

5. Fit new expanding spring, new retaining pin and new retainer (safety bracket) arrow . These parts are available as a repair set and must be renewed each time the pads are changed. 6. Insert the warning contact wire and warning contacts. 7. Firmly press the brake pedal several 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 beddingin period of approx. 200 km! Not until then do they achieve their best friction and wear coefficient. During this period, the brakes should be subjected to full stress when travelling at high speed only in emergencies.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

815

46 50 04 Measuring front brake discs

Measuring the front brake disc lateral runout top of page

Measuring the front brake disc lateral runout

Includes: Measuring the brake disc thickness tolerance Measuring prerequisite: No tilt play at the wheel. Note If necessary, provide the dial gauge holder with the Ate conversion set, order No. 03.9314 5510.3/01 (longer clamping wing screw and, possibly, also a bracket for the dial gauge). Do not damage the 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.g. Ate order No. 03.93145500.3/01, into the brake caliper, align it and secure it by tightening the clamping wing screw. If the brake disc cannot be turned freely, set the brake pads back a little.

3. Secure the dial gauge with some preload. Put the measuring tip against the largest diameter of the brake surface. 4. Turn the brake disc and, when doing so, read off the lateral runout at the dial gauge. Note

46 50 04 Measuring front brake discs

816

einordnung Lateral runout of the removed brake disc: max. 0.03 mm! Wheel hub lateral runout: max. 0.03 mm! The permissible lateral runout of the installed brake disc is max. 0.06 mm! Do not damage the brake hoses or brake lines during removal/installation of the brake caliper! 5. If the brake disc lateral runout exceeds 0,06 mm, mark the position in relation to the wheel hub and remove the brake disc. Check the wheel hub lateral runout.

6. Check the wheel hub lateral runout as described below: Measure 1 x outside arrow and 1 x inside arrow of the wheel bolt area (5point measuring procedure) on the front face of the wheel hub. Fasten the dial gauge using a commercially available universal dial gauge holder (refer to Workshop Equipment Manual, Chapter 2.4, No. 1471). 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 and wheel hub. Next, apply a thin coat of Optimoly TA to the centring surface on the wheel hub. Fasten brake disc on the wheel hub in a different position than before radially offset with respect to the wheel hub. Repeat the measurement with adapter plate 9510/1 fitted. If the lateral runout is still greater than 0.06 mm, replace the brake disc.

Measuring the brake disc thickness tolerance

Measure the brake disc thickness deviation within the brake surface at approx. 8 points by using the micrometer. Thickness tolerance of the brake disc max. 0.02 mm (new condition: max. 0.01 mm).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Measuring the front brake disc lateral runout

817

Removing and installing the front brake disc

Removal Installation top of page

Removal
Note In order to gain better access for assembly work, it is beneficial to turn the wheels fully either to the right or the left! 1. Remove front wheel. Press the electrical lead for the speed sensor/wear indicator out of the holder. 2. Undo the plug coupling for the speed sensor/wear indicator on the wheel carrier. 3. Loosen holder for brake line at wheel carrier. 4. Disengage the electrical lead for the wear indicator from the clips. 5. Set the brake pads back slightly with the piston resetting fixture . 6. Undo the brake caliper on the wheel carrier and hang it in a 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 discs during assembly! Distinguishing characteristic: involute shape and spare part number (SP No.). The flat surface of the brake discs is marked with R = right or L = left. Spare part on lefthand side third group number is odd. Spare part on righthand side third group number is even. For example: SP No. Left brake disc: 996.351.409.02 SP No. Right brake disc: 996.351.410.02. 1. Check that all parts are in perfect condition and replace them if necessary. 2. Clean the levelling and centering surfaces on the brake disc and wheel hub. 3. Apply a very thin coat of Optimoly TA to the centering surface on the wheel hub.

Removing and installing the front brake disc

818

einordnung

4. Fit the brake disc. L Left brake 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, 996651

Installation

819

46 53 04 Measuring rear brake discs

Measuring the rear brake disc lateral runout top of page

Measuring the rear brake disc lateral runout

Includes: Measuring the brake disc thickness tolerance Measuring prerequisite: No tilt play at the wheel. Note If necessary, provide the dial gauge holder with the Ate conversion set, order No. 03.9314 5510.3/01 (longer clamping wing screw and, possibly, also a bracket for the dial gauge). Do not damage the 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.g. Ate order No. 03.93145500.3/01, into the brake caliper, align it and secure it by tightening the clamping wing screw. If the brake disc cannot be turned freely, set the brake pads back a little.

3. Secure the dial gauge with some preload. Put the measuring tip against the largest diameter of the brake surface. 4. Turn the brake disc and, when doing so, read off the lateral runout at the dial gauge. Note

46 53 04 Measuring rear brake discs

820

einordnung Lateral runout of the removed brake disc: max. 0.03 mm! Wheel hub lateral runout: max. 0.03 mm! The permissible lateral runout of the installed brake disc is max. 0.06 mm! Do not damage the brake hoses or brake lines during removal/installation of the brake caliper! 5. If the brake disc lateral runout exceeds 0,06 mm, mark the position in relation to the wheel hub and remove the brake disc. Check the wheel hub lateral runout.

6. Check the wheel hub lateral runout as described below: Measure 1 x outside arrow and 1 x inside arrow of the wheel bolt area (5point measuring procedure) on the front face of the wheel hub. Fasten the dial gauge using a commercially available universal dial gauge holder (refer to Workshop Equipment Manual, Chapter 2.4, No. 1471). 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 and wheel hub. Next, apply a thin coat of Optimoly TA to the centring surface on the wheel hub. Fasten brake disc on the wheel hub in a different position than before radially offset with respect to the wheel hub. Repeat the measurement with adapter plate 9510/1 fitted. If the lateral runout is still greater than 0.06 mm, replace the brake disc.

Measuring the brake disc thickness tolerance

Measure the brake disc thickness deviation within the brake surface at approx. 8 points by using the micrometer. Thickness tolerance of the brake disc max. 0.02 mm (new condition: max. 0.01 mm).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Measuring the rear brake disc lateral runout

821

46 53 19 Removing and installing the rear brake disc

Removal Installation top of page

Removal
1. Remove the rear wheel. Open the plug connection on the wheel carrier and pull out the plug for the brake pad wear indicator.

2. With a screwdriver, turn the adjustment device towards "release" through a wheel bolt threaded hole. 3. Remove the brake caliper from the wheel carrier and suspend it in the wheel arch (do not open brake hydraulics). First, pull out the electrical wires 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 (arrows). If a stuck brake disc cannot be removed by gentle tapping with a plastic hammer, evenly screw hexagonhead bolts into the two M8 threads of the brake disc, thereby pressing off the disc. top of page

Installation
1. Clean the levelling and centering surfaces on the brake disc and wheel hub. Then apply a very thin coat of Optimoly TA to the centering surface on the wheel hub. 2. Fit the brake disc. Note Do not confuse right and left brake discs during assembly. Distinguishing characteristic: involute shape and spare part number (SP No.). The flat surface of the brake discs is marked with R = right or L = left. Spare part on lefthand side third group number is odd (SP No. Left brake disc: 996.352.405.00).

46 53 19 Removing and installing the rear brake disc

822

einordnung

Spare part on righthand side third group number is even (SP No. Right brake disc: 996.352.406.00). 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 ftlb.).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

823

46 83 16 Adjusting the parking brake shoes

Note Check the free play of the parking brake lever Adjusting the parking brake Note Includes: Adjust the parking brake shoes and parking brake cables.

top of page

Check the free play of the parking brake lever

The parkiing brake must be adjusted if the parking brake lever can be pulled up by more than 4 teeth with medium force application without a braking effect being apparent. Note The parking brake has asbestosfree brake linings. The parking brake with asbestosfree brake linings must never be adjusted in such a way that the lining must "grind down" during operation.

top of page

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 turnbuckle accessible, open the cover of the tray behind the parking brake lever and remove the rubber inlay and also the insert.

46 83 16 Adjusting the parking brake shoes

824

einordnung 3. Undo the adjustment nuts arrow on the turnbuckle until the cables are without pretension.

4. With a screwdriver Figure , turn the adjustment device through a wheel bolt threaded hole so that the brake disc can no longer be moved. 5. Turn back the adjustment fixture through 5 notches again (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 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, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Adjusting the parking brake

825

46 83 19 Removing and installing the parking brake shoes

Removal Installation top of page

Removal
1. Remove the rear wheel. Open the plug connection on the wheel carrier and pull out the plug for the brake pad wear indicator.

2. With a screwdriver, turn the adjustment device towards "release" through a wheel bolt threaded hole. 3. Remove the brake caliper from the wheel carrier and suspend it in the wheel arch (do not open brake hydraulics). First, pull out the electrical wires 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 gentle tapping with a plastic hammer, evenly screw hexagonhead bolts into the two M8 threads of the brake disc, thereby pressing off the disc. 5. Remove compression springs, adjustment fixture and return springs. Remove parking brake shoes. top of page

Installation
1. Lightly grease the adjustment device No. 2 , pins No. 8 /No. 9 on the actuating lever (spreading lever) and the sliding surfaces of the parking brake shoes.

46 83 19 Removing and installing the parking brake shoes

826

einordnung

2. Install the actuating lever (spreading lever) No. 12 , brake shoes, return springs, compression springs and adjustment device. The spreading lever (No 12.) is a 1part assembly that cannot be disassembled. This assembly consists of parts No. 6 , No. 7 and No. 8 . Note The hook (the curved end of the spring) of compression spring No. 10 must point upward on the upper brake shoe and downward on the lower brake shoe. 3. Again check to ensure that the parking brake shoes, adjustment device, return springs, compression springs and spreading 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 mirror). 4. Clean the levelling and centering surfaces on the brake disc and wheel hub. Then apply a very thin coat of Optimoly TA to the centering surface on the wheel hub. 5. Fit the brake disc. Note Do not confuse right and left brake discs during assembly. Distinguishing characteristic: involute shape and spare part number (SP No.). The flat surface of the brake discs is marked with R = right or L = left. Spare part on lefthand side third group number is odd (SP No. Left brake disc: 996.352.405.00).

Installation

827

einordnung

Spare part on righthand side third group number is even (SP No. Right brake disc: 996.352.406.00). 6. Adjust the parking brake shoes and 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 fastening screws after each removal.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

828

47 01 07 Bleeding brakes (vehicle with PSM)

PSM Procedure for bleeding 1st step: Bleed brakes as usual 2nd step: Bleeding at front on right with running booster pump top of page

PSM
PSM (Porsche Stability Management) is standard in the 911 Turbo (996). Note Observe brakefluid quality! Use only new DOT4 brake fluid! The brakefluid change interval using Super DOT4 brake fluid is two years! This brake fluid is available under 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 with running booster pump. top of page

1st step: Bleed brakes as usual

CAUTION For vehicles with extremely high mileage or for very old vehicles, damage to the brake master cylinder can occur and the primary boots can be damaged! Double the number of pumping cycles and use only half of the master brake cylinder stroke! 1. Fill reservoir to its top edge with new brake fluid.

47 01 07 Bleeding brakes (vehicle with PSM)

829

einordnung

2. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure approximately 2.0 bar. Note Bleed the outer bleeder valve first! 3. Continue bleeding at the brake calipers in the sequence: Sequence: Rear right / rear left / front left / front right. 4. Open each bleeder valve until clear, bubblefree brake fluid emerges. 5. Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for cleanliness, lack of air bubbles and to determine the brake fluid used. After installing a new brake master cylinder and/or a new hydraulic 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 procedure in the sequence rear left / front right / front left. This will remove all air bubbles (from the primary circuit). Note Also carry out this procedure if the brake hydraulics was largely empty or if after bleeding residual air can be detected by excessive brakepedal travel! 6. Continue bleeding at front on right with running booster pump (Step 2). top of page

2nd step: Bleeding at front on right with running booster pump

CAUTION For vehicles with extremely high mileage or for very old vehicles, damage to the brake master cylinder can occur and the primary boots can be damaged! Double the number of pumping cycles and use only half of the master brake cylinder stroke! Note Bleed brakes as usual! 1st step: Bleed brakes as usual 830

einordnung Do not carry out booster pump activation with the Porsche System Tester 2 until after this has been done (after conventional bleeding) as otherwise damage to the booster pump can occur! To bleed at front on right with running booster pump the bleeding device remains connected (switched on)! Bleeding pressure approximately 2.0 bar! 1. Connect the Porsche System Tester 2 to the diagnostic socket. 2. Switch ignition on. Select the "Bleed" menu in the PSM system. Entry takes place through the ABS system (automatic status change after PSM). 3. Open the front right bleeder valve (use hose and collecting bottle). Note After a certain period of 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 Tester. In this way the booster pump is activated. 5. Bleed until clear, bubblefree brake fluid emerges. 6. In addition (throughout bleeding operation) fully depress (pump) brake pedal as far as the stop at least ten times. 7. Close the right front bleeder valve. Then immediately press the Stop button on the System Tester. In this way pump operation is ended. 8. Switch ignition off and disconnect System Tester.

9. Switch off and disconnect the bleeding device. Correct the brake fluid level if necessary.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

2nd step: Bleeding at front on right with running booster pump

831

47 08 55 Changing brake fluid

Note Procedure for changing brake fluid Note Observe brakefluid quality! Use only new DOT4 brake fluid! The brakefluid change interval using Super DOT4 brake fluid is two years! This brake fluid is available under 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 changing brake fluid

1. Fill reservoir to its top edge with new brake 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 valves! 4. Continue brake fluid change at the brake calipers (no special sequence). 5. Open every bleeder valve until clear, bubblefree brake fluid emerges and until the corresponding change quantity per brake calliper is reached (approximately 250 cm3 ). 6. Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for cleanliness, lack of air bubbles and to determine the brake fluid used.

47 08 55 Changing brake fluid

832

einordnung

7. Switch off and disconnect the bleeding device. Correct the brake fluid level if necessary.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Procedure for changing brake fluid

833

47 15 19 Removing and installing brake master cylinder

Removal Installation top of page

Removal

Note

The booster pump 1 remains fitted (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 electrical line (plug) on the reservoir.

4. Remove suction line of booster pump 2 . 5. 47 15 19 Removing and installing brake master cylinder 834

einordnung Undo the brake lines on the brake master cylinder. Close the brake lines and the brake line connections with suitable plugs. Note A = Brake master cylinder fastening nuts

B = Brake booster fastening screws (Torx)

6. Undo the fastening nuts A of the brake master cylinder. Pull out brake master cylinder. top of page

Installation
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 after this has been done (after conventional bleeding) as otherwise damage to the booster pump can occur! To bleed at front on right with running booster pump the bleeding device remains connected (switched on)! Bleeding pressure approximately 2.0 bar! 3. Carry out a function check of the brakes.

Removal

835

einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

836

47 70 19 Removing and installing brake booster

Removal Installation top of page

Removal

Note

To remove and install brake booster C , the brake master cylinderB , the hydraulic unit D and the booster pump A in vehicles with PSM (GT2 without PSM) must be removed. The assembly of the brake master cylinder B with the brake booster C must not be disconnected for removal and installation 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 fluid using the brake pedal via a front and a rear brake caliper (use collecting bottle). 3. Disconnect the electrical line (plug) on the reservoir.

4. Undo the brake lines on the brake master cylinder. Close the brake lines and the brake line connections with suitable plugs. Undo the fastening nuts A of the brake master cylinder. Pull out 47 70 19 Removing and installing brake booster 837

einordnung brake master cylinder. The brake master cylinder must be disconnected from the brake booster if both parts should continue to be used! A = Brake master cylinder fastening nuts B = Brake booster fastening screws (Torx)

5. In vehicles with PSM, remove the booster pump 1 with the holder1a . For the removal of the booster pump, 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 arrows and disconnect. Remove connector housing rearwards from out of the holder moving arrow . Undo the three plastic fastening nuts 5 and remove the booster pump 1 with the holder 1a . Note In the case of assembly work on the hydraulic 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 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 and may cause faults in the system! 6. Remove hydraulic unit. To remove the hydraulic unit, carry out the following removal procedure: Undo the brake lines on the hydraulic unit. Close the brake lines and the brake line connections with suitable plugs. Pull the plug off the pressure sensor if present (vehicles with PSM 5.7). Unlock/disconnect the control module connector on the hydraulic unit. Cover the plug connection and the plug! Undo and guide out the hydraulic unit. 7. Remove holder of hydraulic unit (if still installed).

Removal

838

einordnung

8. Separate the 2 push rods from each other (loosen). For this purpose, remove the fastening nut (fastening nut, standard as of April 2001)arrow . To make the retainer or the fastening nut accessible, adjust the bellows positioned above the body.

9. Disengage the vacuum line on the brake booster. Undo the fastening screws arrows of the 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 ratio (boost ratio) of the 911 Turbo (996) compared to the 911 GT2. Boost ratio 911 GT2 = 3.15 : 1. Boost ratio 911 Turbo (996) = 3.85 : 1.

1. Install new pushrod (push rod with fastening nut) 12.1 (if not already present) in place of 12 (push rod with retainer). When doing so, observe installation dimension X (138 mm).

Installation

839

einordnung

Basic setting of the push rod dimension X is 138 mm (set in new brake boosters)! If necessary, 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 the 2 push rods. To do so, mount the fastening nuts arrow Note Installation 840

einordnung Adjusting the brake pushrod length changes the position of the brake pedal. Perform a fine adjustment of the brake pushrod if the correct position of the brake pedal is not given! After the brake pushrod is adjusted, check the brake light switch adjustment!

5. Check the postition of the brake pedal Dimension X = 45 + 5 mm . Perform measurement between the centre of the brake pedal plate and the accelerator pedal. Perform a fine adjustment of the brake pushrod if the correct position of the brake pedal is not given.

Fine adjustment of brake pushrods: Undo the lock 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 retighten the the lock nut. 6. Fit the bellows onto the body and fasten with the clamps.

7. Check the setting of the brake light switch 1 . The pedal must move a perceptible distance of approx. 5 to 10 mm before the brake light lights up. At the same time, check (make sure) that the brake light lights up before the pedal meets perceptible resistance or before brake pressure builds up. If necessary, set/readjust 46 Check brakelight setting. 8. Fit the vacuum hose for the brake booster. 9. Install hydraulic unit, boost pump (in vehicles with PSM) and brake master cylinder. Fit all brake lines. Note Installation 841

einordnung Ensure that the reservoir is engaged correctly on the brake master cylinder. 10. Bleed the brakes Serv. No. 47 01 07 (vehicles with PSM) or bleed the brakes GT2 (without PSM) Serv. No. 41 01 07. Note First bleed brakes as usual!

Only afterwards (after the conventional bleeding) should the booster pump control be performed (continue bleeding) with the Porsche System Tester 2 in vehicles with PSM! If this is not observed, damage can occur to the booster pump! To bleed at front on right with running booster pump (PSM), the bleeding device should remain connected (switched on)! Bleeding pressure approximately 2.0 bar! 11. When replacing the hydraulic unit in vehicles with PSM (4channel system), code the control module (manual 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 Porsche System Tester 2 (PST 2). Additionally, perform the static test in the system. Check electrical and hydraulic lines (brake lines) for incorrect assignment using the PST 2. Note The exchange test checks that the brake lines/solenoid valves are assigned to the correct brake calipers (wheels)! Then start the engine. The ABS and if necessary also the PSMrelated lights in the instrument cluster must go out when the engine is running. Carry out a function check of the brakes. Then perform a short test drive and perform at least one ABS control operation, taking the road conditions into consideration. Read out the ABS or PSM fault memory again. There must not be any stored faults.

Installation

842

einordnung

13. Install covers A / B .

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

843

48 10 19 Removing and installing steering wheel

Removal Installation top of page

Removal
Note Replace fastening screws of the airbag unit whenever they have been loosened! The airbag unit must always be set down so that the cushioned side faces upwards! If removed for an extended period, the airbag unit must be kept in a locked place! Observe the safety regulations! To prevent unintended rotation of the contact unit (KE) when the steering wheel has been removed, the contact unit locks itself when the steering 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 this purpose, loosen the two fastening screws arrow with a screwdriver for TORX screwdriver insert T 30 V.A.G 1952 . Disconnect plug connection at airbag unit and at steering wheel (for horn).

3. Loosen hexagon nut arrow and remove together with spring washer. 4. Turn wheels to straightahead position. Then mark the position of the steering wheel with respect to the steering shaft (for refitting). Remove steering wheel (in straightahead position). top of page

48 10 19 Removing and installing steering wheel

844

einordnung

Installation
WARNING Malfunctions of the driver's airbag unit possible! Do not trap the cable of the contact unit. Ensure correct routing! 1. Refit the steering wheel with the wheels in the straightahead 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's airbag unit. Use new fastening screws. Tightening torque: 10 Nm (7.5 ftlb.). 4. Check horn for operation.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

845

48 90 19 Removing and installing steering gear

Removal Installation top of page

Removal
1. Remove underside panel. Note Fix the steering wheel with the wheels in straightahead position or remove the steering wheel with the wheels in straightahead position! If this is not done, the airbag contact unit 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. Press out trackrod ball joint from steering arm. Use special tool pressout tool 9560 C . When loosening the fastening nut, counter with Torx screwdriver 9546 A . 4. Repeat procedure on the other side. 5. Loosen feed and return lines at the steering gear.

48 90 19 Removing and installing steering gear

846

einordnung

For this purpose, loosen the hexagon socket head bolt (arrow) and remove the retainer plate. Plug lines or use collecting container. Cover lines if necessary (danger of soiling). 6. Loosen the two steeringgear fastening screws (on the underside of the cross member). Note Ensure that no damage (scoring) is caused to the steering rack! To loosen and tighten the track rods, secure the steering gear on a suitable plate! 7. Pull out steering gear to the left (to the right for righthand drive vehicles). 8. If necessary, loosen and remove right and left track rods at steering 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 steeringgear fastening screws and the fit bolt of the steering shaft whenever they have been removed. Screw threads must be clean and free of grease. Ensure that no damage (scoring) is caused to the steering rack. Mount the track rods on the steering gear. Then secure the respective bellows with new clamping rings. Push on universal joint (steering shaft) with the steering gear and steering wheel or airbag contact unit (spiral spring) in centre position. For ease of assembly, put steeringgear fastening screws just in place. Observe notes for sliding piece and airbag contact unit! Removal 847

einordnung Observe note on steeringgear centre position in the section describing front track adjustment in Repair Group 44! Note When topping up or filling in Pentosin, make sure that it does not come into contact with the coolant hoses! Observe the specifications in order to avoid overfilling and thus overflowing! If coolant hoses come into contact with Pentosin, thoroughly clean them with water IMMEDIATELY! Replace visibly swollen coolant hoses! After fitting the pressure lines, fill steering hydraulics with Pentosin CHF 11 S and bleed 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 pulled off steering shaft No. 4 , notch No. 2 must point to the tooth gap No. 3 on assembly. WARNING Malfunctions of the driver's airbag unit possible! Do not trap the cable of the contact unit! Ensure correct routing! 2. If the steering wheel was not fixed before the steering gear was removed, the position of the contact unit (spiral spring) may no longer be correct. In this event, remove steering wheel and move contact unit to centre position! Centre position: 3. First move contact unit against the end stop.

Installation

848

einordnung

4. Turn contact unit two revolutions back from the end stop and then continue turning as far as the centre position mark. The exact centre position is indicated by the two No. 1 arrows. 1. Center position mark arrows No. 1 2. Drivers that engage in the steering wheel 3. Locking (securing against turning), which becomes effective after removal of the steering wheel 5. Turn front wheels to straightahead position before fitting the steering wheel (steering shaft mounted on steering gear).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Notes for sliding piece and airbag contact unit

849

50 55 19 Removing and installing the wing

50 55 19 Removing and installing the wing

850

einordnung

Note Before removing the wing, the following parts must be removed: 440519 Removing and installing wheel => Removing and installing wheel housing liners, 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 canister For the left wing, 926019 Removing and installing tank for windscreen washer system 50 55 19 Removing and installing the wing 851

einordnung

No. Designation 1 Plastic bodybound rivet 5.0 x 11.5 2 Rubber sleeve 3 Guide ring 4 5 6 7 8 9 10 11 12 Tank lock Sleeve Collar nut M6 x 20 Angle piece Plastic clip Collar screw M6 x 20 Collar nut M6 Wing brace Torx sheetmetal screw T 20 Protective film Sheetmetal screw St 6.3 x 12 Sheetmetal nut Wing

Qty. Removal 1 Press out pin in the centre of the rivet head. 1 1 1 1 1 1 1 2 2 1 Pull off. Press lug A and disengage. Press lugs of the sleeve B and disengage.

Installation

Press in.

Tightening torque: 10 Nm (7.5 ftlb.)

Press apart lugs C and pull off. Undo two turns.

13 14 15 16

1 4 11 1

Replace

Pull out downwards at the Insert the wing under the lid hinge at the Apillar and remove to the front, fit the sheetmetal screws. Adjust front. contours and joining dimensions (see: Serv. No. 5 Diagram, Body joining plan) to the door and covers, tighten sheetmetal screws 14, 12 .

17 Sheetmetal nut 17 18 Retaining strip

2 1 Undo the collar nuts10 Fix retaining strip on the wing upward to the out of the restraining strip. stop and fasten with the collar nuts 10 . Tightening torque:10 Nm (7.5 ftlb.) Pull off. Replace. Press lug and separate.

19 Transparent protective film 20 Electrical plug connection 20 21 Emergency cable

1 1 1

50 55 19 Removing and installing the wing

852

einordnung 22 Sheetmetal screw B 4.2 x 18 23 Servo motor 2 1

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

50 55 19 Removing and installing the wing

853

50 56 19 Removing and installing wheel housing liners, front

50 56 19 Removing and installing wheel housing liners, front

854

einordnung

No. 1 2 3 4 5 6

Designation Front left wheel housing liner, front Front left wheel housing liner, rear Sheetmetal nut B4.8 12 Expanding rivet St 6.3 Combination screw B4.8 x 16 Plastic nut T5 22 x 10

Qty. 1 1

Removal

Installation

Adjust to centre of hole. 1 Check, replace if necessary.

Check, replace if necessary.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

50 56 19 Removing and installing wheel housing liners, front

855

53 69 19 Removing and installing wheel housing liners, rear

53 69 19 Removing and installing wheel housing liners, rear

856

einordnung

No. 1 2 3 4 5

Designation Rear left wheel housing liner, front Rear left wheel housing liner, rear Sheetmetal screw 3 Plastic nut T5. Sheetmetal nut

Qty. 1 1 7 5 2

Removal Installation Pull out downwards. Pull out downwards. Undo Undo. Inspect and replace if necessary.

996420, 996421, 996450, 996451, 996840, 996841

53 69 19 Removing and installing wheel housing liners, rear

857

55 10 37 Disassembling and assembling release for 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 Disassembling and assembling release for front lid

858

einordnung

No. Procedure 1 Releasing hexagon socket head bolts 2 2 Removing sill 1

3 4

Instructions Remove plastic plugs 3 and undo the hexagon socket head bolts 2 from the sill by approx. 4 5 threads. Lift sill 1 upwards out of the bottom support with a plastic spatula and press out. Check fastening clips 4 , replace if necessary. Pulling off plug connections 5, Pull off plug connections 5, 6 on the actuating switches of the 6 of the actuating switches lids. Removing actuating switches for Press the fastening ribs of the sill arrows outward with a front lid 7, 8 screwdriver and unclip the actuating switch of the front lid 7 .

top of page

Disassembling release for front cover

859

einordnung

Assembling release for front cover

No. Procedure 1 Installing actuating switch for front lid 7 2 Joining plug connections 5, 6 of the actuating switches 3 Attaching sill 1 4

Instructions Clip locking tabs of the actuating switch for the front lid 7 into the fastening ribs of the sill. Push plug connections 5, 6 onto the actuating switches of the lids. Clip in new fastening clips 4 if necessary. Insert sill 1 downward into the lower support and engage. Tightening hexagon socket head Screw in hexagon socket head bolts 2 of the sill by approx. 4 bolts 2 5 threads. Seal holes of the sill with plastic plugs 3 .

Assembling release for front cover

860

einordnung

Removing and installing support for cap release

Shown on the Boxster

Note In order to remove the support for the cap release, the front seat must be removed. 720119 Removing and installing front seat

No. Designation 1 Fastening screw 2 Support for cap release 3 Locating pin 4 5 Felt support Plastic nut

Qty. Removal 2 Unscrew. 1 1 1 1 Pull out the pin. Pull off.

Installation Screw in. Preassembled dowel pin 3 is pressed in with the support 2 into the body. Press in the pin. Check, if necessary, replace.

top of page

Removing and installing support for cap release

Item 1

Special tool designation Remarks Removal tool for Nr. 131 removing retaining Commercially available tools Gr. 2.4; clips Workshop Equipment Manual

Removing and installing support for cap release

861

einordnung 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Removing and installing support for cap release

862

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

einordnung

No. 1

Designation Electrical plug connection lock side

Qty. 1

Removal Turn in direction of arrow A and extend.

2 3

Electrical plug connection Hexagonhead bolt

1 2

4 5

Cover panel

Lower part of lid lock 1

Installation Position electrical plug connection on the lock panel and turn in direction of arrow B . At arrow C , press and disconnect. Plug in the electrical plug connection. Undo. Screw in. Tightening torque: 10 Nm (7.5 ftlb.) Separate from lower part of lid lock. Position on lower part of lid lock. Undo. Position on closing panel.

55 17 19 Removing and installing front lower part of lid lock

864

einordnung 6 Bowden cable 1 Disengage nipple of the bowden cable Press in bowden cable 6 and press the cover out of the cover 6 and engage lower part of the lock. the nipple in the lower part of the lock. Press bowden cable 7 ouf of the Press bowden cable 7 lower part of the lid lock. into the lower part of the lid lock. Turn bowden cable 8 in the => Installing engine direction of the arrow and remove cover release from the servo motor 9 . => Removing engine cover release => Installing engine cover release

Bowden cable emergency release Bowden cable emergency release USA and Canada vehicles only Servo motor emergency release USA and Canada vehicles only

top of page

Removing and installing bowden cable for lock actuation

Removing and installing bowden cable for lock actuation

865

einordnung

No. Designation 1 Hexagonhead bolt 2 Cover panel 3

Qty. Removal 2 Back off by 2 turns. 1 Lift out of the lower part of the lid lock. Disconnect. Pull off. Disengage nipple of bowden cable 51 and press the cover out of the lower part of the lid lock. Pull the rubber sleeve arrow A out of the closing panel.

Installation Tightening torque:10 Nm (7.5 ftlb.) Position on lower part of lid lock. Connect. Push on. Pull the rubber sleeve arrow A in through the opening of the closing panel. Press in bowden cable cover 51 and engage the nipple into the lower part of the lid lock. 866

Electrical plug 1 connection 4 Guide for bowden 1 cable 51 Bowden cable 1

Removing and installing bowden cable for lock actuation

einordnung 6 Servo motor for lid opener 1 Extend bowden cable 52 out of the stamp of the servo motor. Insert bowden cable 52 into the stamp of the servo motor.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Removing and installing bowden cable for lock actuation

867

55 22 19 Removing and installing front lid

55 22 19 Removing and installing front lid

868

einordnung

No. Designation 1 Combination screw M6 x 14 2 Lid

Qty. Removal 4

Installation Tightening torque: 10 Nm (7.5 ftlb.)

Undo combination screws 1 Position lid 2 on the left and right hinges from the hinge and remove lid and adjust according to the lid contour to the 2 . left side section.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

55 22 19 Removing and installing front lid

869

55 22 37 Disassembling and assembling front lid

55 22 37 Disassembling and assembling front lid

870

einordnung

No. 1

Designation Lid

Qty. 1

Removal

2 3

Rubber buffer

Unscrew rubber pads 2 .

Installation Adjust lid 1 to the hinges in accordance with the contours of the wings and the front spoiler. Screw in rubber pads 2 .

Selfadhesive 1 label tyre pressure Combination 2 screw M6 x 12 Upper part of lock

Tightening torque: 10 Nm (7.5 ftlb.)

Tapping nut

Take upper part of lock Fasten upper part of lock 5 to the lid 5 off lid 1 . 1 with the combination screws 4 and adjust to the lower part of lock. Replace. 871

55 22 37 Disassembling and assembling front lid

einordnung Unscrew tapping nut 6 of lid badge. Remove base 8 of lid Insert base 8 and lid badge 7 into the badge 7 . lid and fasten with tapping nut 6 . 1

7 8

Badge on lid Base

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

55 22 37 Disassembling and assembling front lid

872

55 25 19 Removing and installing front lid hinge

55 25 19 Removing and installing front lid hinge

873

einordnung

No. 1 2 3

Designation Clip

Qty. 4

Removal Press out with a narrow screwdriver. Undo fastening screws 3 from the hinge 4 .

Installation Press in.

Pneumatic spring 4 Combination 4 screw M6 x 14

Position hinge 4 on the body and screw in place with the fastening screws 3 . Tightening torque: 10 Nm (7.5 ftlb.)

Hinge

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

55 25 19 Removing and installing front lid hinge

874

55 37 19 Removing and installing filler flap

55 37 19 Removing and installing filler flap

875

einordnung

No. 1

Designation Filler flap

Qty. 1

Removal Insert a narrow screwdriver from above in front of the clip arrow , press the fastening lug backwards and hold, and carefully pull off the filler flap upwards.

Plastic hinge

Installation Position filler flap on the wing cutout and press in until the fastening lugs engage. Insert the disassembly tool at the locking lugs on the Position the left and right and lift via the locking lugs, push the plastic hinge at plastic hinge against the disassembly tool and detach the filler flap and from the filler flap. push on until it engages perceptibly.

55 37 19 Removing and installing filler flap

876

einordnung 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

55 37 19 Removing and installing filler flap

877

55 57 37 Disassembling 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 for rear lid

878

einordnung

No. Procedure 1 Undoing hexagon socket head bolts 2 2 Removing sill 1

3 4

Instructions Remove plastic plugs 3 and undo the hexagon socket head bolts 2 from the sill by approx. 4 5 threads. Lift sill 1 upwards out of the bottom support with a plastic spatula and press out. Check fastening clips 4 , replace if necessary. Pulling off plug connections 5, Pull off plug connections 5, 6 on the actuating switches of the 6 of the actuating switches lids. Removing actuating switches for Press the fastening ribs of the sill arrows outward with a rear lid 7, 8 screwdriver and unclip the actuating switch of the rear lid 7 .

top of page

Disassembling release for rear lid

879

einordnung

Assembling release for rear lid

No. Procedure 1 Installing actuating switch for rear lid 7 2 Joining plug connections 5, 6 of the actuating switches 3 Putting on sill cover 1 4

Instructions Clip locking tabs of the actuating switch for the rear lid 7 into the fastening ribs of the sill. Push plug connections 5, 6 onto the actuating switches of the lids. Clip in new fastening clips 4 if necessary. Insert sill 1 downward into the lower support and engage. Tightening hexagon socket head Screw in hexagon socket head bolts 2 of the sill by approx. 4 bolts 2 5 threads. Seal holes of the sill with plastic plugs 3 .

Assembling release for rear lid

880

einordnung 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Assembling release for rear lid

881

55 86 19 Removing and installing lower part of lid lock

55 86 19 Removing and installing lower part of lid lock

882

einordnung

No. 1

Designation Undo fastening screws 1

Qty. 2

Removal

Installation Tightening torque: 10 Nm (7.5 ftlb.)

2 3 4 5 6 7

Lower part of lid lock Servo motor unit Retaining clip Emergency release cable Electrical plug connection Electrical plug connection

1 1 1 1 1 1

Undo fastening screws 1 from the servo motor unit 3 . Press out. Press in.

Interior lighting plug connection. Press lug arrow and separate. Servo motor unit electrical plug connection. Press Connect lugs arrow of the plug 7 and separate. coded plug 883

55 86 19 Removing and installing lower part of lid lock

einordnung 7 .

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

55 86 19 Removing and installing lower part of lid lock

884

55 90 19 Removing and installing rear lid

55 90 19 Removing and installing rear lid

885

einordnung

No. Designation 1 Electrical plug connection 2 Hexagonhead bolt M6 x 16 Rear lid

Qty. Removal 1 Press the lug of the electrical plug connection 1 and separate. 4 Undo.

Installation Connect electrical plug connection 1 .

Tightening torque: 10 Nm (7.5 ftlb.)

Adjust lid 3 to the hinges in accordance with the contours of the wings and the front spoiler.

996420, 996421, 996450, 996451

55 90 19 Removing and installing rear lid

886

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

einordnung

DANGER Danger of injury/damage during assembly work on the hydraulic system! The hydraulic system 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 case of contact with skin/eyes. Open banjo bolts very slowly, otherwise oil which spills out may spray! Note 667237 Disassembling and assembling pump unit

Disassembling rear lid

888

einordnung No. Procedure 1 Remove spoiler Remove rear lid 2 Remove additional brake light 3 3 Pull off rubber cover 4 4 Remove adjusting element 5 Remove upper part of lock 8 Instructions 665819 Removing and installing rear spoiler => Removing and installing rear lid Disengage cover A at the sides, unlock lock B . Remove brake light and disconnect plug connection C .

Unscrew rubber pad 5 and disengage collar 6 . Unscrew fastening screws 7 and remove upper part of lock 8 .

No. 6

Procedure Remove air guide 9

Instructions Unscrew fastening screws 8 and remove air guide 9 . 889

Disassembling rear lid

einordnung 7 Remove fan with fan housing Disconnect plug connections for fan and engine compartment 11 lighting on the fan housing. Unscrew fastening screws 10 and remove fan with fan housing 11 . Undo mount 13 Unscrew fastening screws 12 . Remove pump unit 17 Pull mount 13 gently forwards and unscrew the fastening with extension elements screws 16 of the pump unit 17 . Remove mount 13 . 15l and 15r Unscrew the fastening screws 14 of the extension elements 15l and 15r . Remove pump unit with extension elements. Note: Do not kink hydraulic lines! Remove additional brake Unscrew fastening screws 18 . Take off additional brake light holder 19 light holder 19 . Pull off model logo

8 9

10

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Assembling rear lid

Assembling rear lid

890

einordnung

No. Procedure 1 Install additional brake light holder 19 2 Install pump unit 17 with extension elements 15l and 15r

3 4

Instructions Insert additional brake light holder 19 . Screw in fastening screws 18 and tighten to 10 Nm (7.5 ftlb.) . Insert plug connection of the brake light under the additional brake light holder 19 . Put on pump unit with extension elements. Note: Extension element with microswitch must be located on the righthand 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 tighten handtight . Fit mount 13 and fasten pump unit 17 with fastening screws 16 and tighten to 10 Nm (7.5 ftlb.) . Fasten mount 13 Tighten fastening screws 12 to 10 Nm (7.5 ftlb.) . Install fan with fan Position fan with fan housing 11 , fasten with fastening screws 10 and housing 11 tighten to 10 Nm (7.5 ftlb.) . Connect plugs for fan and engine compartment lighting on the fan housing.

Assembling rear lid

891

einordnung 5 Remove air guide 9 Unscrew fastening screws 8 and remove air guide 9 .

No. 6 7 8 9

Procedure Install upper part of lock 8 Install adjusting element Install rubber cover 4 Install additional brake light 3 Install rear lid Install spoiler Check installation position of the extension elements and tighten the

Instructions Position upper part of lock 8 and fasten with fastening screws 7 . Engage collar 6 . Screw in rubber pads 5 . Push on plug C . Insert brake light. Lock the lock B . Engage cover A . => Removing and installing rear lid 665819 Removing and installing rear spoiler The spoiler must be installed free of tension. If necessary, correct the installation position by shifting 892

10 11

Assembling rear lid

einordnung fastening screws. Stick on model logo the extension elements. Tighten fastening screws arrows to 10 Nm (7.5 ftlb.) . => 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, 996421, 996450, 996451

Replacing the model logo

893

55 91 19 Removing and installing lid hinge

55 91 19 Removing and installing lid hinge

894

einordnung

No. Designation Qty. Removal 1 Pneumatic spring 1 Press in lugs at the sides. right cable sleeve 2 Fuse 4 Press out with a narrow screwdriver. 3 Pneumatic spring 2 left/right 4 Stop clip 2 left/right 5 Combination 4 screw M6 x 16 6 Lid hinge, right 1 Undo combination screws 5 . 55 91 19 Removing and installing lid hinge

Installation Press together until the lugs engage at the sides. Press in.

Tightening torque: 10 Nm (7.5 ftlb.)

Adjust to the right side section in accordance with lid contour. 895

einordnung 7 Lid hinge, left 1 Undo combination screws 5 . Adjust to the left side section in accordance with lid contour.

996420, 996421, 996450, 996451, 996840, 996841

55 91 19 Removing and installing lid hinge

896

57 11 37 Disassembling and assembling door handle

57 11 37 Disassembling and assembling door handle

897

einordnung

CAUTION There is a danger of injury if fingers or hands are trapped by the door window when the comfort function is triggered: lower and raise door window! When carrying out assembly work in the area 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 1 Shift sliding piece of the piece connection piece and unclip actuating shaft 8 . 3 Handle liner 1 Pull out handle liner downward at an angle. 57 11 37 Disassembling and assembling door handle 898

einordnung 4 5 6 7 8 Base Microswitch Circlip Pin Actuating shaft 1 1 1 1 1 Unclip. Unclip. Press out. Pull pin 7 out of the handle 13 and remove actuating shaft. Clip in. Clip in. Press in. Position actuating shaft on the handle No. 13 . Insert pin 7 and secure pin with the circlip 6 . Replace.

9 10 11 12 13

S retainer Pin rod Eccentric Return spring Handle

1 1 1 1 1

Pull pin rod 10 out of the handle liner 3 and separate handle from the handle liner. Pull off.

14 Buffer 15 Door handle bottom part

2 1

Position return spring 12 , eccentric 11 and handle on the handle liner 3 , insert the pin rod 10 and secure retainer 9 . Replace.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

57 11 37 Disassembling and assembling door handle

899

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

einordnung

CAUTION Damage to the bowden cable when removing door trim panel! Damage by bending the bowden cable at the hook! Pull the hook out of the end piece only after installation in the inner door release!

No. Designation Qty. Removal 1 Door trim 1 705919 Removing and installing door panel trim panel 2 Bowden 1 Door handle side: cable 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 .

Installation

Door handle side: Engage bowden cable in the door handle 2 . Pull the hook out of the end piece of the sleeve only after installation in the door handle. Plastic clip into the door 901

57 37 19 Removing and installing inner door release (bowden cable) for door lock

einordnung Lock side: Inset X Unclip bowden cable from the door lock C . Swivel bowden cable by 90 A and pull it out of 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, 996840, 996841

57 37 19 Removing and installing inner door release (bowden cable) for door lock

902

57 45 19 Removing and installing door handle

Removing and installing orientation lighting (LED lightemitting diodes)

57 45 19 Removing and installing door handle

903

einordnung

No. Designation 1 Door trim panel 2 Return spring 2 3 Sleeve 4 Ovalhead screw 4.2 x 13 5 Door handle 5

Qty. Removal 705919 Removing and installing door trim panel 1 Unclip from the door handle 5 and the door trim panel 1 . 1 Pull off from the return spring 2 . 4

Installation

Clip into the door handle 5 and the door trim panel 1 . Put onto the return spring 2 .

Undo ovalhead screws 4 and pull Insert door handle 5 into the door the door handle out of the door trim trim panel 1 from the rear and panel 1 . position it. Screw tight with the ovalhead screws 4 .

57 45 19 Removing and installing door handle

904

einordnung top of page

Removing and installing orientation lighting (LED lightemitting diodes)

Removing orientation lighting (LED lightemitting diodes)

No. Procedure 1 Remove lightemitting diode housing 2 2 Remove lightemitting diode housing 1

Instructions Pull lightemitting diode housing 2 to the rear out of the locks on the cover 3 . Pull cover at front out of the door handle. Raise the lug arrow of the lightemitting diode housing 1 and pull it out in a downward direction. 905

Removing and installing orientation lighting (LED lightemitting diodes)

einordnung 3 Pull LED unit out into the door handle Pull LED unit out of the door handle to the rear.

Installing orientation lighting (LED lightemitting diodes)

No. Procedure 1 Insert LED unit into the door handle 2 Install lightemitting diode housing 1 3 Install lightemitting diode housing 2

Instructions Insert LED unit into the door handle from the rear. Insert the lightemitting diode housing 1 into the guide of the door handle until the lug arrow engages. Position the lightemitting diode housing 2 into the door handle. The cable arrow A must point downwards. Push cover 3 into the 906

Removing orientation lighting (LED lightemitting diodes)

einordnung door handle from the front until there is no more play on the lock of the lightemitting diode housing.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Installing orientation lighting (LED lightemitting diodes)

907

60 14 15 Reteaching the lifting/sliding roof drive

It is necessary to reteach the lifting/sliding roof in the event of emergency operation or replacement of parts on the lifting/sliding roof (seals, slidingroof drive) or if the entire system is replaced. The data of limit positions and characteristics are stored and are retained even if the battery is disconnected. Teaching lifting/sliding roof drive 1. With the ignition switched on, press the lift button and move the lifting/sliding roof drive to the "raised" limit position. 2. Press lift button again and keep depressed. After around 10 seconds, a complete cycle takes place from the raised limit position to the positions "lower open close". Teaching 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 moved to the limit position first. 3. If the lifting/sliding roof drive should move back in Item 1, then the closing force limitation function has responded (lifting/sliding force drive was taught). The open button must be retaught in this case. Teaching lifting/sliding roof drive 1 Press the open button until the sliding roof stops. Then release the button. Press the open button again until the lifting/sliding roof drive stops again. Then release the button. 2 Press the open button again and keep depressed. The entire process takes place after approx. 10 seconds: "close lift lower open close".

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

60 14 15 Reteaching the lifting/sliding roof drive

908

60 14 19 Removing and installing lifting/sliding roof drive

Removing lifting/sliding roof drive Installing lifting/sliding roof drive Emergency operation on lifting/sliding roof drive top of page

Removing lifting/sliding roof drive

1. Using a small screwdriver, carefully unclip both cover lenses at the 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 fastening screws arrows Torx T25 and take lifting/sliding roof drive down and off the teeth. 4. Push lifting/sliding roof drive in the roof member trim to the side and take out to the bottom. Disconnect the electrical plug connection. top of page

60 14 19 Removing and installing lifting/sliding roof drive

909

einordnung

Installing lifting/sliding roof drive

Note Do not press on or touch the transmission/reception diodes with your fingers! The cover lenses must not be soiled or smudged with grease. 1. Engage electrical plug connection and carefully lay the wire (do not pinch). Note Always replace the fastening screws of the lifting/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 arrows . Tightening torque: 6 Nm (4.5 ftlb.)

3. Engage cover on the windscreen frame at front and push rearward. Unclip locking tabs arrows B of the cover on the left and right. Tighten fastening screws with a crosshead screwdriver A . 4. Fit cover lenses. top of page

Installing lifting/sliding roof drive

910

einordnung

Emergency operation on lifting/sliding roof drive

The lifting/sliding roof drive can also be operated manually if the electric drive should fail. Check fuse D 3 before 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 be operated again after emergency operation.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Emergency operation on lifting/sliding roof drive

911

60 28 19 Removing and installing frame for sliding roof

Removing frame for sliding roof Installing frame for sliding roof

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Removing frame for sliding roof

60 28 19 Removing and installing frame for sliding roof

912

einordnung

Note Due to additional body structure reinforcements in the roof, the connection points for the sliding roof frame have changed in vehicles produced as from production date 01.01.2001. In these vehicles, the holders at the side of the sliding 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 frame. CAUTION Danger of damage to the seats during the removal of the sliding roof frame! During removal of the sliding roof frame, move both seats to the rear and tilt the backrests to the rear.

Removing frame for sliding roof

913

einordnung No. Procedure Removing sliding roof panel Removing roof lining 1 Pull off water drain hoses 2 Disconnect the electrical plug connection 3 Unscrew the front fastening screws A 4a Unscrew the fastening screws B, C at the side (vehicles without roof frame reinforcement in the body structure) 4b Unscrew the fastening screws B at the side (vehicles with roof frame reinforcement in the body structure) Remove the sliding roof frame from the vehicle Instructions => Removing and installing sliding roof panel 708419 Removing and installing roof lining Disconnect water drain hoses at the front and rear from the water drain brackets of the frame for the sliding roof. Press in the locking tabs arrows on both sides and pull off the electrical plug connection. Unscrew the fastening screws at the front of the sliding roof frame. Unscrew the fastening screw from the sliding roof frame at the side and the fastening screws from the retaining bracket on the roof frame at the side.

Undo the fastening screws from the frame for the sliding roof at the sides.

Remove the sliding roof frame with an assistant and pull it out of the passenger compartment through the door aperture.

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Installing frame for sliding roof

Installing frame for sliding roof

914

einordnung

No. Procedure Prefit side holder 1 on the sliding roof frame (only vehicles without roof frame reinforcement in the body structure) Insert frame for sliding roof into the vehicle 1a Screw in the fastening screws B at the side (vehicles without roof frame reinforcement in the body structure) 1b

Instructions Position side holder for sliding roof frame and fasten with fastening screws D . Only tighten screws slightly, so that the holder can still be shifted.

Insert sliding roof frame with an assistant into the passenger compartment through the door aperture and position at the screwmounting points. Position the fastening screw of the sliding roof frame at the side and the fastening screws of the retaining bracket on the roof frame at the side and tighten by hand.

Installing frame for sliding roof

915

einordnung Screw in the fastening Position the fastening screw of the sliding roof frame at the side and screws B at the side tighten by hand. (vehicles with roof frame reinforcement in the body structure) 2 Screw in the front Position the fastening screws on the sliding roof frame at the front and fastening screws A tighten by hand. 2a Screw in the fastening Position the fastening screws of the retaining brackets C . Align the screws of the holder C retaining bracket laterally with the sliding roof frame and the roof at the side frame arrows . Tighten the fastening screws of the retaining (vehicles without roof brackets D with the correct tightening torque according to the frame reinforcement in following table. the body structure) Tighten the fastening Tighten all fastening screws according to the following table. screws with the correct tightening torque 3 Connecting electrical plug Plug in the electrical plug connection. The locking tabs arrow E connection must engage on both sides when the connection is made. 4 Push on water drain hoses Push the water drain hoses at the front and rear onto the water drain brackets of the frame for the sliding roof. Installing sliding roof => Removing and installing sliding roof panel panel Installing roof lining 708419 Removing and installing roof lining

Tightening torques

Location Fastening screw, sliding roof frame to roof frame reinforcement Fastening screw, sliding roof holder to roof frame, at side Fastening screw, sliding roof frame holder to sliding roof frame

Tightening torque Nm Illustration Thread (ftlb.) A M6 7.5 (5.5) B, C D M6 M6 7,5 (5.5) 7.5 (5.5)

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Tightening torques

916

60 28 37 Disassembling 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 frame for sliding roof

917

einordnung

The following accessories must be removed for the work operation "Disassembling and assembling frame for sliding roof"! 708419 Removing and installing roof lining 602819 Removing and installing frame for sliding roof Note The following parts must be transferred from the sliding roof frame to be replaced to the new sliding roof frame: Lifting/sliding roof drive, draught deflector, frame clips

No. Procedure 1 Removing draught deflector 2 Removing frame clips 3 Removing lifting/sliding roof drive

Instructions Fold the draught deflector up, press it inwards and out of the guides at the left and right sides and pull it out. Press in the left and right tabs of the frame clip A . Unscrew both Torx T25 fastening screws and take lifting/sliding roof drive down and off the teeth of the sliding roof frame. 918

Disassembling frame for sliding roof

einordnung 601419 Removing and installing lifting/sliding roof drive

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Assembling frame for sliding roof

No. Procedure 1 Fitting frame clips 2 Fitting lifting/sliding roof drive

Instructions Press the frame clips A in until the left and right tabs engage. Position lifting/sliding roof drive into the teeth of the frame. Screw in with the Torx T25 fastening screws and tighten. Tightening torque:6 Nm (4.5 ftlb.) 601419 Removing and installing lifting/sliding roof drive 601415 Reteaching the lifting/sliding drive

Assembling frame for sliding roof

919

einordnung 3 Fitting draught deflector Press 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

Assembling frame for sliding roof

920

60 40 19 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 panel

921

einordnung

CAUTION Damage to rear water drainage channel or to the sliding roof mechanism when the sliding roof panel is removed and when moving the trim of the sliding/tilting roof (Item 4) The sliding roof frame must not be moved to the "Open" position when the sliding roof panel has been removed. The trim of the sliding/tilting roof (Item 4) must be shifted without the use of force.

No. 1 2

Procedure Open sliding roof panel Disengage sliding/tilting roof trim Move sliding roof panel to tilting position

Instructions Open the sliding roof panel approx. 80 mm. Disengage (press) trim of sliding/tilting roof out of the left and righthand front catches towards the rear and out of the drivers, and push back by approx. 30 mm. Close the sliding roof panel and move to tilting position.

60 40 19 Removing and installing sliding roof panel

922

einordnung 4 5 6 Sliding/tilting roof trim Close sliding roof panel Remove sliding roof panel Push trim of sliding/tilting roof back evenly on the left and right as far as it will go. Move the sliding roof panel to zero position (closed). Unscrew fastening screws 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 1 Insert sliding roof panel

Instructions Push gate (inset) back on the left and right. Insert the sliding roof panel in the sliding roof frame and screw in fastening screws T25 slightly. 923

60 40 19 Removing and installing sliding roof panel

einordnung 2 Adjust the sliding roof panel in line with the roof contour: lower at the front dimension A by up to 1.0 mm and higher at the rear dimension B by up to +1.0 mm. Tighten fastening screws Torx T25. Tightening torque 6 Nm (4.5 ftlb.) Move sliding roof Move sliding roof panel to tilting position. Carefully pull trim of the panel to tilting sliding/tilting roof forwards evenly on the left and right until it is approx. position, check inner 40 mm in front of the roof edge cutout. Check whether the left and panels righthand inner side panels Figure C have engaged. If inner panels are damaged or have become detached from the groove of the sliding roof frame, take off the trim of the sliding/tilting roof with the sliding roof panel removed and replace the inner panels if necessary. See: Additional instructions for fitting the inner panels Close sliding roof Move the sliding roof panel to zero position (closed). panel Engage sliding/tilting Push sliding/tilting roof trim forward as far as the roof edge cutout. While roof trim doing so, take care not to push trim of sliding/tilting roof upwards. This could detach or damage the inner panels. Open sliding roof Open sliding roof panel approx. 80 mm. Pull trim of sliding/tilting roof panel forward until the left and righthand drivers engage. Close sliding roof panel. Function test: The trim of the sliding/tilting roof lies against the rear of the sliding roof panel in tilting position. Close sliding roof panel. The trim of the sliding/tilting roof must lie against the clamping frame of the roof lining on the front, right and left with a slight degree of pretension. The trim of the sliding/tilting roof must not lie against the rear cross bar of the roof lining. A gap of approx. 0.5 mm (cheque card thickness) must be left. There is no gap at the rear cross member and the roof lining in vehicles with a fully coated (flocked) clamping frame. Adjust sliding roof panel

4 5

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Additional instructions for removing the inner panels

Note When the inner panels are being removed or replaced, the sliding roof panel and sliding/tilting roof trim should be removed and the gate of the roof frame should be extended (tilting position). Removing inner panels

Additional instructions for removing the inner panels

924

einordnung Position the sliding/tilting roof trim dimension A approx. 80 mm in front of the roof edge cutout.

Disengage left and right inner side panels. Pull out the connector springs B on the gate and pull the sliding/tilting roof trim upwards.

Push the sides of the inner panels out of 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 frame. Check function by sliding longitudinally.

Pull out the connector springs B on the gate and push in sliding/tilting roof trim. Push inner panels under the sheetmetal panel of the sliding/tilting roof trim.

Additional instructions for fitting the inner panels

925

einordnung

Position the sliding/tilting roof trim dimension A approx. 80 mm in front of the roof edge cutout.

Engage the left and righthand inner side panels in the sliding/tilting roof trim. Repeat the procedure for installing the sliding roof panel.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Additional instructions for fitting the inner panels

926

63 10 19 Removing and installing front bumper

Removing and installing front bumper

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Removing and installing front bumper

63 10 19 Removing and installing front bumper

927

einordnung

No. Designation 1 Collar nut 2 Retaining strip, centre 3 Left and right retaining strip

Qty. Removal 9 1 Undo collar nut 1 and remove centre retaining strip 1 Undo the collar nut 1 and sheetmetal screw 4 out of the retaining strip

Note: Installation Fix retaining strip on the transverse lock panel and fasten with the collar nuts 1 . Tightening torque:10 Nm (7.5 ftlb.) Position retaining strip on the wing upward so that the clearance rib rests against the side section without gaps, and tighten with the collar nuts 1 and the sheetmetal screw 4 . Tightening torque:10 Nm (7.5 ftlb.) Tightening torque:3 Nm (2 ftlb.)

Sheetmetal screw St 4.8 x 19

Removing and installing front bumper

928

einordnung 5 6 7 Spacer sleeve 5.2 x 14 Sheetmetal nut St 4.8 Protective foil left, transparent foil on right Hexagonhead bolt M12 x 1.5 x 100 Bumper mount 2 4 2 Inspect and replace if necessary. Inspect and replace if necessary.

8 9

2 1 Undo hexagonhead bolt 8 from the bumper mount and remove. Undo Undo combination screw 10 and remove impact pipe and seal. Undo combination screw 10 and remove impact absorber and seal.

Tightening torque:85 Nm (63 ftlb.) Attach the bumper mount to the impact pipes 11, 11A and fix it in position. Fasten it with the hexagonhead bolt 8 . Tightening torque:23 Nm (17 ftlb.) Fix the impact pipe to the body with the seal and fasten with the combination screw 10 . Fix the impact absorber to the body with the seal and fasten with the combination screw 10 . Inspect and replace if necessary. Inspect and replace if necessary.

10 Combination screw 4 M8 x 30 11 Impact pipe 2

11A USA version, impact absorber 12 Seal, impact pipe 12A USA version, impact absorber seal

2 2

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Removing and installing front bumper

929

63 15 19 Removing and installing front spoiler

Removing front spoiler Installing front spoiler

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Removing front spoiler

63 15 19 Removing and installing front spoiler

930

einordnung

Note Before removing the front spoiler the 505619 Removing and installing wheel housing liner must be removed!

No. Procedure 1 Remove cover. 2

Instructions Turn hexagon cap nut 2 by 45 and remove. Undo sheetmetal screws 4 from the front part 1 . Remove direction Press in spring clip of direction indicator light arrow A at the sides with indicator light. a screwdriver and take out the direction indicator light 5 , disconnect electrical connection. Undo front spoiler at On the front spoiler, undo the sheetmetal screws 6 and spacer sleeve the sides. 7 from the retaining strips on the left and right.

Removing front spoiler

931

einordnung 4 5 Press out temperature Press temperature sensor 9 out of the inlet grille. sensor. Undo front spoiler on Undo fastening screws 10 of the front spoiler on the underbody. the underbody. Remove front spoiler 1 to the front.

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Installing front spoiler

No. Procedure 1 Fit front spoiler 1 .

Instructions Lift the front spoiler 1 near the headlights above the radiators on the right and left. Note: When inserting over the radiators, make sure that the covers are not pressed out of the front spoiler! 932

Installing front spoiler

einordnung 2 3 4 5 Fit front spoiler on the underbody. Fit front spoiler at the sides. Fit cover. Fit direction indicator light. Press in temperature sensor Position front spoiler on the underbody and screw in place with the fastening screws 10 . Affix front spoiler to the retaining strip and fasten it with the sheetmetal screw 6 and spacer sleeve 7 . Fasten the front end 1 with the sheetmetal screws 4 . Affix cover 3 , turn hexagon cap nuts 2 by 45. Connect electrical plug connection of the direction indicator light 5 . Insert lug arrow of the direction indicator light into the front end 1 and clip into the sheetmetal clip. Press temperature sensor into the inlet grille.

996420, 996421, 996450, 996451, 996430, 996431

Installing front spoiler

933

63 15 37 Disassembling and assembling front spoiler

Disassembling front spoiler Assembling front spoiler

63 15 37 Disassembling and assembling front spoiler

934

einordnung

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Disassembling front spoiler

No. Procedure 1 Remove covering cap 2 .

2 3 4

Remove covering frame 4 . Remove frame centre 5 . Grille frame 7 left, right

Instructions Gently press out covering cap 2 with a screwdriver. Cut through the securing cord of the covering cap 2 and the front end 1 . Pull off protective film 3 . Press in the lugs of the covering frame 4 and lift it up and off carefully. Carefully disengage the lugs of the frame centre 5 on all sides using a screwdriver. Press retaining clip 6 out at the sides with a screwdriver and remove. Carefully disengage the lug of the grille frame 935

Disassembling front spoiler

einordnung 7 on all sides using a screwdriver. Carefully disengage the lugs of the grille frame 7A on all sides using a screwdriver. Remove hexagonhead bolt 10A and the hexagon socket head bolts 8A from the spacer9A , remove impact horn 12A . Note: the retaining bracket 11A must be destroyed in order to remove it. The holding pegs in the front end must be cut off.

Install USA version grille frame 7A and impact horn 12A on the left and right.

Removing front spoiler

Note Removing front spoiler 936

einordnung The spoiler trim can be removed without removing the front spoiler!

No. Procedure 1 Undo fastening screws 3 . 2 Remove sheetmetal frame 2 3 Remove front spoiler 1 . .

Instructions Undo fastening screws 3 from the front spoiler 1 at the sides. Pull sheetmetal frame 2 out of the lower rib of the front spoiler 1 . Press in the lugs with a screwdriver, at the same time pull off the front spoiler 1 outwards.

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Assembling front spoiler

Assembling front spoiler

937

einordnung

No. Procedure 1 Install USA version grille frame 7A and impact horn 12A

2 3 4 5

Install grille frame 7 Install frame centre 5 Install covering frame 4 Install covering cap

Instructions Position the retaining bracket 11A on the front end 1 . Melt the holding pegs in the front end with a soldering iron. Fasten the impact horn 12A to the retaining bracket 11A with the hexagonhead bolt 10A . Position spacer 9A on the inside of the front end. With the hexagon socket head bolts 8A , screw the impact horn 12A through the retaining bracket 11A . Lock grille frame 7A on all sides Lock grille frame 7 on all sides in the front end1 Press retaining clip 6 onto the front end 1 and the grille frame. Lock frame centre 5 on all sides in the front end 1 . Lock covering frame 4 into the front end 1 . Pull securing cord into the eyelet of the covering cap 2 and front end 1 . 938

Assembling front spoiler

einordnung Position protective film 3 in the extension of the grille rib running vertically on the inside and affix.

Installing front spoiler

No. Procedure 1 Fit front spoiler 1 . 2 3 Tighten front spoiler 1 Fit sheetmetal frame 2 .

Instructions Insert the front spoiler 1 into the groove of the front end. Make sure that all lugs are engaged. Use the fastening screws 3 and spacer sleeve 4 to tighten the front spoiler at the sides. Push the sheetmetal frame 2 into the lower rib of the front spoiler.

Installing front spoiler

939

einordnung

996420, 996421, 996450, 996451

Installing front spoiler

940

63 50 19 Removing and installing rear bumper

Removing rear bumper Installing rear bumper Additional assembly instructions for installation of the bumper Additional assembly instructions for installation of the bumper Carrera 4S Tightening torques

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Removing rear bumper

63 50 19 Removing and installing rear bumper

941

einordnung

No. Procedure Removing rear spoiler 1 Remove retaining strip at the sides 2

2 3

Instructions => Removing rear spoiler The instructions, => Removing and installing frame with heat shield must be used for the 996 Carrera 4S. Remove collar nuts 1 and the retaining strips at the sides 2 . Pull off antichafing film 3 . Pull off sheetmetal nut 4 . Removing centre Screw off collar nuts 6 and remove centre retaining strip 5 . Check retaining strip 5 sheetmetal nuts 7 , replace if necessary. Remove and Unscrew sheetmetal screws 11 and fastening screws 10 , remove disassemble rear rear bumper 8, (8A) with fitted heat shield 9 . Unscrew fastening bumper 8, or (8A) screws 12 , remove heat shield at the bottom centre 9 and rear (USA version) support 14 . If necessary, disassemble the rear support by unscrewing the fastening screws 13 . Removing centre heat Screw off collar nuts 17 and remove centre heat shield on top18 . shield on top 18 942

Removing rear bumper

einordnung 5 Remove impact pipe 19 or impact absorber (USA version) 19 A Remove heat shield at the sides 23 Unscrew fastening screws 21 , remove impact pipe 19 or impact absorber 19 A with seal 20 or 20 A .

Unscrew collar nuts 22 and remove the heat shield at the 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 installing the exhaust system The exhaust system must be removed in type 996 Carrera 4S. See: 996 Carrera 4S Technical Manual 260119 Removing and installing the exhaust system

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Installing rear bumper

Installing rear bumper

943

einordnung

CAUTION Damage will result if deformed heat shields are fitted! Damaged or 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 bumper, check the heat shields for leaks.

No. Procedure 1 Install centre heat shield on top 18 2 Install heat shield at the sides 23

Instructions Screw on centre heat shield on top 18 with collar nuts 17 . Position heat shield at the sides 23 from below and screw on with collar nuts 22 .

Installing rear bumper

944

einordnung 3 Install impact pipe 19 or impact absorber (USA version) 19 A Position impact pipe 19 or impact absorber 19 A with seal 20 or 20 A and screw on with fastening screws 21 . => Tightening torques Install rear bumper 8, or (8A) Position the heat shield9 together with the rear support (USA version) 14 and screw on using fastening screws 12 . => Tightening torques Position connecting angle 15 and screw on using fastening screws 13 . Position the rear bumper 8, (8A) with the mounted heat shield 9 and screw on with fastening screws 10 . => Tightening torquesScrew in sheetmetal screws 11 . Check the adjustment dimensions of the => Additional assembly instructions for installation of rear bumper and the assembly of the the bumper heat shield and correct if necessary Installing centre retaining strip 5 Position centre retaining 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 instructions for installation of the bumper Carrera 4S Put on antichafing film 3 Put on sheetmetal nut 4 and align. Stick on antichafing film 3 with clearance U = 8 mm . Note: make sure that the antichafing film seals off the recess of the sheetmetal nut completely. Install retaining strip at the sides 2 Put on retaining strip at the sides 2 so that the clearance rib arrow of the retaining strip rests against the side section without gaps and screw on with the collar nuts 1 . Use the instructions => Removing and installing frame with heat shield for type Carrera 4S. Installing rear spoiler => Install rear spoiler

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Additional assembly instructions for installation of the bumper

Adjustment dimensions of the bumper

Additional assembly instructions for installation of the bumper

945

einordnung

Note In order to reduce adjustment work to a minimum when assembling the rear spoiler, the rear bumper or centre retaining strip must be aligned with the lower edge of the rear lid according to the dimensions shown above. However, the precondition for precise positioning of the components is that the rear lid is optimally adjusted and correctly locked 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 to the joining plan. 2. Adjust the rear bumper 8, 8A on both sides to dimension Y = 140 mm . The measurements can be changed by undoing or moving the impact pipes or impact absorbers (USA version). 3. Adjust the centre retaining strip 5 according to dimension X = 147 mm .

Correct assembly of the heat shields

Adjustment dimensions of the bumper

946

einordnung

CAUTION Damage will result if heat shields are fitted incorrectly! Observe the following points during assembly! Make sure the heat shields overlap correctly. There should not be any continuous gaps along the entire length of the heat shields. A gap of up to 2 mm wide and 30 mm long is permissible locally. At least more than 80 % of the total 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 of the lower retaining strip. 1. After assembly of the rear spoiler, check that there is a gap dimension W >. 50 mm between the shield of the exhaust system 24 and the lower retaining strip 25 . Check heat shield projection Z = 0 4 mm . top of page

Additional assembly instructions for installation of the bumper Carrera 4S

Correct assembly of the heat shields

Correct assembly of the heat shields

947

einordnung

CAUTION Damage will result if heat shields are fitted incorrectly! Observe the following points during assembly! Make sure the heat shields overlap correctly. There should not be any continuous gaps along the entire length of the heat shields. A gap of up to 2 mm wide and 30 mm long is permissible locally. At least more than 80 % of the total 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 of the lower retaining strip. 1. After assembly of the rear spoiler, check that there is a gap dimension of W = min. 70 mm between the shield of the exhaust system 24 and the lower retaining strip 25 . The dimension is measured diagonally upwards.

Removing and installing frame with heat shield

Correct assembly of the heat shields

948

einordnung

Removing the heat shield Unscrew collar nuts 1 and fastening screw 11 , remove the frame with heat shield 27 . Installing the heat shield Position the frame with the heat shield 27 so that the clearance rib arrow rests against the retaining strip without gaps. Tighten the collar nuts 1 and fastening screw 11 . top of page

Tightening torques

Location Fastening screws of impact pipe on body Fastening screws of rear supports on rear bumper Fastening screws of bumper on impact pipes

Illustration 21 12 10

Thread M8 M6

Tightening torque 23 Nm (17 ftlb.) 10 Nm (7.5 ftlb.) 85 Nm (63 ftlb.)

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Removing and installing frame with heat shield

949

63 55 19 Removing and installing rear spoiler

Removing rear spoiler Install rear spoiler

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Removing rear spoiler

63 55 19 Removing and installing rear spoiler

950

einordnung

No. Procedure Remove tail light 1 Remove impact horns (only USA version) 2A

2 3 4

Remove cover moulding 6 and sheetmetal screws 7 Unscrew sheetmetal screws 8 Disconnect plug connection 9 Remove rear spoiler

Instructions 943319 Removing and installing bulb for rear light Unclip closure cap 1A , undo fastening screws 3A and remove impact horn 2A . Note: the fastening screws 3A can remain on the bumper with the washers 2A . Unscrew sheetmetal screws 5 and sheetmetal screws 7 . Remove cover moulding 6 . Unscrew sheetmetal screws 8 .

Removing rear spoiler

951

einordnung top of page

Install rear spoiler

CAUTION Damage will result if deformed heat shields are fitted! Damaged or 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 rear spoiler, check the heat shields for leaks.

No. Procedure

Instructions

Install rear spoiler

952

einordnung Check the heat shields on the vehicle Observe safety instructions! before fitting the rear spoiler Replace heat shields if necessary. Check that the heat shields are properly fitted and correct if necessary. => Removing and installing rear bumper Check antichafing film 10 Check antichafing film 10 for leaks and damage, replace antichafing film if necessary. => Installing rear bumper Check adjustment dimensions of => Additional assembly instructions for installation of the bumper and rear end support, correct bumper if necessary Join plug connection 9 Position rear spoiler on the vehicle Make sure that it is fitted free on tension. Adjust the joining line of the rear spoiler as shown in the joining plan. Fit cover moulding 6 Put on cover moulding 6 and fasten rear spoiler with sheetmetal screws 5 and sheetmetal screws 7 . Screw in sheetmetal screws 8 Fasten rear spoiler with sheetmetal screws 8 . Fit impact horns (only USA version) Put on impact horn 2A , align at the sides and tighten 2A fastening screws 4A to 23 Nm (17 ftlb.) . Unclip closure cap 1A . Note: when putting on the impact horns, make sure the washers 3A are placed between the screw head and the bearing surface of the impact horn. Install rear light 943319 Removing and installing bulb for rear light Check the heat shields on the vehicle Observe safety instructions! after fitting the rear spoiler Check that the heat shields are properly fitted and correct if necessary. => Removing and installing rear bumper Check gap dimensions Y , Z of Projection from rear spoiler: Y = 11.5 16.5 mm the tailpipes, or adjust tailpipes Distance from rear spoiler: Z > 20 mm Centre distance at the sides evenly to the left and right.

3 4 5

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Install rear spoiler

953

63 55 37 Disassembling and assembling rear spoiler

Disassembling rear spoiler Assembling rear spoiler Additional instructions for replacing the rear spoiler

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Disassembling rear spoiler

63 55 37 Disassembling and assembling rear spoiler

954

einordnung

Note When removing the air outlet grille 17 , do not undo the retaining clips by using the screwdriver between the retaining clip and the rear end ribs! Use new retaining clips 18 for installation!

No. Procedure Removing rear spoiler 1 Remove shield cover 1 2 Remove lower retaining strip 5

Instructions => Removing rear spoiler Press off clamping washers 4 with a suitable tool, remove shield 3 and shield cover 1 with rivet bolt 2 . Bore out rivets 6 and lower retaining strip 5 .

Disassembling rear spoiler

955

einordnung 3 Remove cover 11 for towing lug (not USA version!) Remove ParkAssistent sensor 7 (only version with ParkAssistent!) Remove licence plate light Remove air outlet grille 17

Disengage ParkAssistent sensor 7 and remove with isolating ring 8 . Disengage installation housing 9 . The retainer plate 10 remains on the rear spoiler. 917519 Removing and installing sensor for ParkAssistent Unscrew fastening screws 12 , remove cover 13 and housing 14 . Remove licence plate light with wiring harness 15 . Unclip bodybound rivets for licence plate holder 16 . Move retaining clips 18 as far as possible to one side and open up retaining clip with a screwdriver. Remove retaining clips 18 . Remove the air outlet grille 17 . Do not undo the retaining clips by using the screwdriver between the retaining clip and the rear end ribs! Do not damage the fastening ribs of the rear spoiler! Use new retaining clips for installation!

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Assembling rear spoiler

Assembling rear spoiler

956

einordnung

No. Procedure 1 Install air outlet grille 17 2 Install licence plate light

Clip in cover 11 for towing lug (not USA version!)

Instructions Put on air outlet grille 17 , align and fasten by pressing new retaining clips 18 onto the rear end ribs. Clean the bearing surfaces of the wiring harness retainer on the inside of the rear spoiler. 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 the fastening screws 12 . Clip in bodybound rivets for licence plate holder 16 . Make sure the rubber sleeve of the licence plate light is installed correctly. Pull in new securing cord and secure.

Assembling rear spoiler

957

einordnung 4 Install ParkAssistent sensor 7 (only version with ParkAssistent!) Install lower retaining strip 5 Install shield cover 2 Engage installation housing 9 . Engage ParkAssistent sensor 7 with isolating ring 8 . 917519 Removing and installing sensor for ParkAssistent

5 6

Push up lower retaining strip 5 and fasten with rivets 6 .

Insert shield 3 and shield cover 2 with rivet bolts 1 . Press on new clamping washers 3 . Note: make sure that the system is free of gaps. Install rear spoiler => Install rear spoiler

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Additional instructions for replacing the rear spoiler

Note Additional cutouts must be made for the impact horns (USA version) in the rear spoiler before the new component is painted. For the ParkAssistent equipment version, no additional bore must be made on the new component. A special spare part is available for this version which contains the bores and retainer plates to hold the ParkAssistent. 1. Drill hole C in accordance with the markings inside the rear spoiler. 2. Saw out cutouts B in accordance with the markings inside the rear spoiler. 3. Slant the upper and lower cut edges of the cutouts B at an angle of 40 (see cut AA ).

Additional instructions for replacing the rear spoiler

958

einordnung 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Additional instructions for replacing the rear spoiler

959

64 86 01 Checking function of heating for rear window

Check with the temperature probe top of page

Check with the temperature probe

Note The function of the heating for the rear window can be checked with a temperature probe with digital display (see Workshop Equipment Manual). The indicator light in the rocker switch also lights up if a fault is present and the heating wires 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 of the sensor for this measurement procedure! After switching on at room temperature and a period of 2 minutes, the temperature must increase by approx. 2 degrees! If no temperature increase is shown, the fault must be detected on the basis of the wiring diagram!

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

64 86 01 Checking function of heating for rear window

960

64 86 19 Removing and installing rear window

Removing rear window 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 car windows!

64 86 19 Removing and installing rear window

961

einordnung Cutting out glued car windows may lead to cut injuries to the skin and the eyes due to flying glass splinters and 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 with the power supply disconnected in order to ensure that the cutter cannot be switched on accidentally. 1. Removing the left and righthand Cpillar trim 705719 Removing and installing trim of A, B and Cpillars 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 the plug connection of the rear window heater Pull off the plug for the rear window heater on the rear window. 5. Opening door windows Lower the door windows. Note The door windows must not be closed until after the curing time has elapsed.

6. Pulling off cover section Detach the cover section 1 from the surrounding section of the rear window and pull off. Note If the cover section is removed from the surrounding section undamaged, it can be reused.

Removing rear window

962

einordnung

7. Removing rear window Remove windscreen with the cutting wire separator. Use pull handle A8 when cutting. The procedure for removing car windows is described in => Removing glass with cutting wire separator. 8. Taking off rear window 9. Pulling off surrounding section a. Carefully detach the surrounding section from the rear window. Note If the surrounding section is removed from the rear window undamaged, it can be reused.

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Preparing the window section for installation

1. Removing adhesive from the body When removing remaining adhesive 2 with the cutting tool C and the flashing knife D on the body, ensure that a surface coating of adhesive remains 3 . Note The surface coating of adhesive residue helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.

Preparing the window section for installation

963

einordnung

2. Cleaning and priming paint damage or newly builtup paint areas in the window aperture of the body Clean new paint areas or damage to the top coat paint in the nonvisible area of the glass section in the body with cleaning solution H1 and patch with primer H2 . Note A ventilation period of at least 10 minutes must be observed between the cleaning of the glass section and the application of the primer! No cleaning solution residues may remain on the body.

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Installing rear window

CAUTION Danger of material damage if specified curing time of adhesive is not observed! The vehicle must not be used until 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 10C Fixing time: approx. 1 hour Note The removed rear window can be reinstalled if there was no prior damage to the rear window and the rear window was removed without damage.

Installing rear window

964

einordnung

1. Fitting surrounding section and cover section Place surrounding section 4 on the rear window and press cover section 1 into the groove of the surrounding section 4 . Note If the surrounding section and cover section were removed from the rear window undamaged, they can be reused. 2. Preparing 2component bonding material for processing => Processing of Porsche 2component window bonding agents Note The bonding material has an open time of 15 min , which means that the bonding material must be applied and 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 processing.

Installing rear window

965

einordnung 3. Applying adhesive to the rear window Apply 2component bonding material with the adhesive gun A to the rear window along the cover section as a triangular bead measuring X = approx. 15 mm . Note When applying the adhesive, it is essential to ensure that the adhesive bead overlaps by approx. 30 mm at the beginning and at the end.

4. Inserting rear window into the body Note Two persons are needed to insert and adjust the rear window. 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 which has oozed out must be removed immediately and the affected fields of vision must be cleaned using cleaning agent H1 . 7. Plugging in rear window heater Plug in the rear window heater. 8. Installing rear window wiper Put on the spring washer and wiper arm. Screw wiper arm on with the fastening nut. Close the cap. 9. Installing rear wall lining 10. Installing left and righthand Cpillar trim Installing rear window 966

einordnung 705719 Removing and installing trim of A, B and Cpillars 11. Closing door windows Note The door windows must not be closed until after the curing time has elapsed.

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Overview of tools and materials

The following tools and materials are required for removal and installation of the rear window with 2component adhesive:

Item A B

Designation Double cartridge gun VAS 5237 Pipette VAG 1344

Source Remarks See Workshop Equipment Manual, Chapter 3.5 See Workshop Equipment Manual,

Overview of tools and materials

967

einordnung Chapter 3.5 See Workshop Equipment Manual, Chapter 3.5 Contains set components H1H8

C D H

Special electric cutter (fine) VAG 1561 A Flashing knife, Utype 639.031.130.22 2component window bonding agent 000.043.300.94

Item H1 H2 H3 H4

Designation Cleaning solution Primer Activator Swab

Item H5 H6 H7 H8

Designation Cartridge, component A Cartridge, component B Mixing nozzle Processing nozzle

Item A

Designation Source Glass separating tool VAG 1474 See Workshop Equipment Manual, B Chapter 3.5 Cutting thread See Parts Catalogue in Main Group 8

Remarks Contains set components A1A9

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Overview of tools and materials

968

66 13 19 Removing and installing air inlet

Removing air inlet Installing air inlet

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Removing air inlet

66 13 19 Removing and installing air inlet

969

einordnung

No. Procedure 1 Remove air inlet 1 2 Remove retaining clips 3 3 Pull off seal 4

Instructions Lift up air inlet 1 at the front edge evenly using an assembly wedge, disengage and pull forwards out of the air duct. 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 must be replaced for installation. Pull off seal 4 . Pull off spring clips 5 .

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Installing air inlet

Removing air inlet

970

einordnung

No. Procedure 1 Push on seal 4

Instructions Check seal 4 and spring clips 5 , replace if necessary. Attach spring clips 5 to the air inlet. Push seal 4 onto the air inlet. Install retaining clips 3 Put new retaining clips 3 onto the tabs of the side section and align evenly in the lug bores. Screw in sheetmetal screws 2 . 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 evenly into the retaining clips. Check air inlet system on the side section 5 Diagram body gap dimensions and check the gap dimension The air inlet system or the gap dimension can be corrected by undoing and shifting the spring clips. 971

Installing air inlet

einordnung

996420, 996421, 996450, 996451, 996840, 996841

Installing air inlet

972

66 36 19 Removing and installing roof joint strip

Removing roof joint strip Installing roof joint strip

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Removing roof joint strip

66 36 19 Removing and installing roof joint strip

973

einordnung

No. Procedure 1 Unclip roof joint strip 2 Pull off roof joint seal 3 Disengage roof joint clips 3 4 5 6

Instructions Lift at both ends using a plastic spatula 1 and unclip all the way along. Pull the roof joint seal out of the groove of the roof joint strip 2 . On the outside of the roof joint clip 3 and roof joint strip, insert a narrow screwdriver in the centre and press the screwdriver outward until the roof joint clip disengages. Unclip foldout element Insert a screwdriver beneath both ends of the foldout element 4 , and 4 lever out. Detach spreader 5 Insert a plastic spatula into the wedge piece of the spreader 5 and push. Remove the spreader. Remove inner linings Lift up the clothes hook bracket 6 at the bottom with a plastic spatula 7, 8 and pull off. Pull away the A and Cpillar trim towards the inside and remove. Detach the roof liner Unclip the metal strut 9 of the roof liner from the plastic clips. 974

Removing roof joint strip

einordnung 8 Detach base plate of Unscrew hexagon socket head bushing a/f 8 (microencapsulated) 12 Roof Transport System . Remove the base plate 11 from the roof channel. 11 .

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Installing roof joint strip

No. 1

Procedure Fit base plate of Roof Transport System 11

Instructions The contact surface of the base plate must be free from dirt and grease. Position the base plate of the Roof Transport System in the roof channel parallel to the roof channel. Tighten hexagon socket head bushing a/f 8 12 (microencapsulated). 975

Installing roof joint strip

einordnung 2 3 Attach roof liner Fit inner lining 7, 8 Push the metal strut 9 of the roof liner into the plastic clips. Position and clip in A and Ppillar trim. Fit the clothes hook bracket 6 . The clothes hook bracket must be inserted into the aluminium bracket without the use of force, otherwise the aluminium bracket is deformed. Fit spreaders 5 Position spreaders 5 (5 per roof channel) in the recesses, beginning at the front. Press the spreader right down into the roof channel, and push the wedge piece into the spreader until the latter is braced in the roof channel. Fit roof joint seal Push the roof joint seal onto the roof joint strip 2 all the way round. Clip in foldout elements Position the foldout element 4 in the cutout of the roof 4 joint strip, and press in the lugs at the ends until they lock into place. Engage roof joint clips 3 Insert the roof joint clips 3 narrow side first and press in until the lug in the center locks into place. Fit roof joint strip 13 Position the roof joint strip 13 over the roof channel, and align the roof joint clips in the roof joint strip with the spreaders so that they lie directly above one another. Push on the roof joint strip.

5 6

7 8

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Installing roof joint strip

976

66 58 19 Removing and installing rear spoiler

Removing rear spoiler Installing rear spoiler

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Removing rear spoiler

66 58 19 Removing and installing rear spoiler

977

einordnung

Note The spoiler can only be removed from the rear lid when the extension elements are extended. After retracting or extending three times with an obstacle, the control module detects the obstacle and switches off. The control module is reset by switching the ignition off and on. In order to remove the spoiler in the case 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 sure to observe the exact sequence for emergency release of the drive module! During emergency release, the extension element retracts suddenly! Wear gloves during emergency release. Before release, cover off the painted areas of the lid near the extension elements with adhesive tape in Removing rear spoiler 978

einordnung order to avoid paint damage. During emergency release, the spoiler must be held tightly by an assistant.

No. Procedure 1 Extend spoiler 1 (with drive module intact) 2 Lift up spoiler 1 (if drive module is faulty)

Instructions Extend spoiler manually using the rocker switch with the ignition switched on. Pull spoiler upwards and push in two support pads 2 approx. 60 mm high on the right and left between the rear lid and the spoiler. Note: use suitable packaging material (e.g. styropore pad, cardboard) as a support pad. The support pads should only be pushed in to the positions shown in the figure. Align the bore on the outer tube of the extension element arrow with the bore of the closure peg 4 by turning the outer tube 3 . The outer tube should be turned in an anticlockwise direction only. Insert hook wrench No. 80/1, 2.4 Workshop Manual into the bores and turn clockwise by 90. Insert hook wrench No. 80/1, 2.4 Workshop Manual into the bores and turn clockwise by 90. Lift the spoiler up and off.

Position outer tubes of the extension elements

4 5

Unlock right extension element Unlock left extension element Remove spoiler 1

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Installing rear spoiler

Installing rear spoiler

979

einordnung

No. 1 2

Procedure Put on spoiler 1 Lock spoiler 1

Cover bore of closure peg

Retract spoiler 1

Instructions Put spoiler 1 on both extension elements. Insert hook wrench No. 80/1, 2.4 Workshop Manual into the bores and turn anticlockwise until the closure peg engages in the lock of the spoiler, then turn anticlockwise by a further 90 until the lock locks. Lock spoiler on both sides. Cover off bore of closure peg 4 by gently turning the outer tube 3 . Note: the outer tube 3 should be turned in an anticlockwise direction only! The visible bores should lie in front in the direction of travel. The outer tube may need to be turned by a further 180. Retract spoiler manually using the rocker switch with the ignition switched on.

Installing rear spoiler

980

einordnung

996420, 996421, 996450, 996451

Installing rear spoiler

981

66 78 01 Checking function of heating for mirror glass

Note Check with the temperature probe Note The function of the heating for the mirror glass can be checked with a temperature probe with digital display (see Workshop Equipment Manual)! The indicator light in the rocker switch also lights up if a fault is present and the 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 switching on at room temperature and a period of 1 minute, the temperature must increase by approx. 2 degrees! If no temperature increase is shown, the fault must be detected on the basis of the wiring diagram!

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

66 78 01 Checking function of heating for mirror glass

982

66 89 19 Removing and installing rearview mirror

Removing the rearview mirror Installing the rearview mirror

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Removing the rearview mirror

66 89 19 Removing and installing rearview mirror

983

einordnung

No. Procedure 1 Remove cover 1 2 Disconnect the plug connection of the adjustment button 2 Disconnect the plug connection of the mirror housing 5 Remove mirror housing 8

Instructions Disengage cover 1 on the underside arrow A and unhook it upwards out of the door triangle arrow B . Press the safety catches arrows of the plug connection 2 and pull the plug out. Disconnect the plug connection of the mirror housing 5 .

Pull off seal 4 . Unscrew fastening screws 6 and remove mirror housing 8 . Press off sealing strip 9 and pull filler piece 7 upwards and out. Check fastening clips 10 , replace if necessary.

top of page Removing the rearview mirror 984

einordnung

Installing the rearview mirror

No. 1

Procedure Install mirror housing 7

3 4

Instructions Press the sealing strip 9 off and insert the bracket of the filler piece 7 downwards. Position the filler piece 7 in the mirror triangle. Position mirror housing 8 and fasten with fastening screws 6 . Connect the plug connection Stick on seal 4 . Check sealing grommet 11 and replace if of the mirror housing 4 necessary; connect the plug connection of the mirror housing 5 . Position the sealing grommet 11 in the mirror triangle. Connect the plug connection Connect plug connection 2 . Check the proper engagement of the adjustment button 2 of the plug connection. Install cover 1 Hook cover 1 into the door triangle from above arrow A and press into the fastening clips on the underside arrow B . 985

Installing the rearview mirror

einordnung

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Installing the rearview mirror

986

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

einordnung

No. Designation 1 Cover, front left 2 Clip 3 Cover, centre left 4 Fastening screws 5 Lock support 6 Lock barrel

Qty. Removal 1 Unclip. 28 1 3 1 1

Installation Clip in. Check, replace if necessary Clip in.

Unclip.

Press in the locking tabs in inset C and Press the lock barrel 6 in to the guide the lock barrel 6 upwards out of lock support 5 until the latter the lock support 5 . engages in the locking tabs. From the bracket 9 (see: inset A ), raise the locking tab with a screwdriver Clip into the bracket 9 .

7 8

Plastic nut 7 Microswitch 1

68 17 37 Disassembling and assembling centre console

988

einordnung and unclip. Press the locking tabs of the bracket 9 Position bracket 9 on the lock together with pointednose pliers inset support 5 and clip into place. B and guide out of the lock support 5 . Ensure that the locking tabs engage properly. Unclip. Clip in. Unclip. Clip in.

Bracket

10 Cover, rear left 11 Cover, rear top 12 Fastening screws 13 Extension bracket

1 1 4 1

Unscrew fastening screws 12 from the extension bracket 13 and guide out of the centre console towards the rear.

Position the extension bracket 13 on the centre console and secure with the fastening screws12 .

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Disassembling and assembling cover for the oddments tray

No. Designation 1 Fastening screws 2 Cover, oddments tray 3 Fastening screws 4 Retaining bracket

Qty. Removal 8 1 2 1

Installation

Undo the fastening screws 3 . Note: the retaining bracket is under tension due to the spring 7 .

Insert the retaining bracket 4 in to the limiting band 8 . Position together on the centre console and secure with the 989

Disassembling and assembling cover for the oddments tray

einordnung Guide the retaining bracket 4 out of the limiting band 8 . Press the hinge pin 5 out and remove the spring 7 or the lower section of the oddments tray cover 6 . fastening screws 3 . Position the spring 7 and the lower section of the oddments tray cover 6 together on the centre console. Press the hinge pin 5 into place.

Hinge pin

7 8

Lower section of oddments tray cover Spring Limiting band

1 1

Unclip the limiting band 8 from Clip the retaining pin together with the centre console together with the the limiting band 8 into the centre retaining pin. console.

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Disassembling and assembling cover for the oddments tray

990

68 23 19 Removing and installing sun visors

Removing sun visors Installing sun visors

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Removing sun visors

68 23 19 Removing and installing sun visors

991

einordnung

1. Detach sun visor Detach the sun visor from the thrust bearing and pull out 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, 996450, 996451, 996840, 996841, 996430, 996431

Removing sun visors

992

68 23 37 Disassembling and assembling sun visor

Disassembling sun visor Assembling sun visor

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Disassembling sun visor

68 23 37 Disassembling and assembling sun visor

993

einordnung

No. Procedure Instructions 1 Unclip mirror insert 3 Insert a narrow screwdriver between the mirror insert 3 and the mirror housing 2 at the bottom centre, and unclip the mirror insert. 2 Remove mirror insert Pull the mirror insert 3 upwards and remove from the mirror housing 3 2 . 3 Remove bulb 5 and Remove the Sofitte 12V/3W bulb 5 from the contact clip 4 . Take contact clips 4 the contact clips upwards out of the holder. 4 Unclip mirror housing Insert a narrow plastic spatula between the mirror housing 2 and the 2 sun visor 1 on the left and right and unclip the mirror housing. 5 Remove mirror housing Take the electric lead out of the mirror housing 2 and detach the 2 mirror housing from the sun visor.

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Disassembling sun visor

994

einordnung

Assembling sun visor

No. 1 2 3 4 5

Procedure Insert mirror housing 2 Press in mirror housing 2 Insert contact clips 4 and bulb 5 Position mirror insert 3 Clip in mirror insert 3

Instructions Insert electric lead into the mirror housing 2 . Position the mirror housing in the sun visor. Press the mirror housing 2 at all four corners until it locks into place. Position the contact clips 4 in the mirror housing and fit under the lug. Insert Sofitte 12V/3W bulb 5 . Position the lugs on the left and right of the mirror insert 3 into the mirror housing 2 . Clip the mirror insert 3 into the mirror housing 2 on the left, right and in the centre. 995

Assembling sun visor

einordnung

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Assembling sun visor

996

68 27 13 Bonding on the interior rearview mirror

Bonding the assembled interior mirror onto the windscreen The following materials are 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 part number top of page

Bonding the assembled interior mirror onto the windscreen

68 27 13 Bonding on the interior rearview mirror

997

einordnung

Note When using the primer, the drying time of 15 20 minutes must be observed! When using the activator, the drying time of 2 minutes must be observed! During adhesion, observe the presson 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 Mark the position of the bonding plate on the outside of the windscreen. interior mirror Dimension A = 633 mm, Bonding the assembled interior mirror onto the windscreen 998

einordnung dimension B = 100 mm Remove adhesive Remove adhesive residues from the windscreen mechanically using a residues scraper. Remove adhesive residues on the bonding plate of the interior mirror mechanically using a scraper. Sand the bonding plate Sand the bonding plate of the interior mirror flat mechanically using 100 of the interior mirror flat grain sandpaper. Clean the bonding plate Clean the bonding plate of the interior mirror with cleaning solution (A). of the interior mirror Clean the bonding area Clean the bonding area on the windscreen with cleaning solution (A). on the windscreen Mask the bonding area Mask the bonding area on the windscreen with primer template (cover on the windscreen film C). The marking for the position of the interior mirror must be visible in the center of the primer template. Prime the bonding area Treat the masked bonding area on the windscreen thinly and evenly on the windscreen using primer (B). Activate the bonding Spray activator (D) onto the bonding area of the windscreen. area on the windscreen Remove the primer template Apply adhesive to the Apply a drop of adhesive (E) to the bonding plate of the interior mirror. bonding plate Stick on the interior Press the interior mirror with the bonding plate onto the primed and mirror activated area of the windscreen.

4 5

6 7

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Bonding the assembled interior mirror onto the windscreen

999

68 27 19 Removing and installing the interior rearview mirror

Removing the interior rearview mirror Installing the interior rearview mirror

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Removing the interior rearview mirror

68 27 19 Removing and installing the interior rearview mirror

1000

einordnung

No. Procedure 1 Secure the pliers and detach the mirror

Remove the mirror

Instructions Set the pliers with the projecting plastic parts to the windscreen to the diameter of the mirror 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. Unclip the base of the interior rearview mirror from the retainer plate on the windscreen.

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Removing the interior rearview mirror

1001

einordnung

Installing the interior rearview mirror

Note The small aluminium chip in the locking area must be removed after the interior rearview 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 area of the mirror base for signs of wear and replace the mirror if necessary.

Installing the interior rearview mirror

1002

einordnung No. Procedure 1 Check locking area 2 Insert the mirror 3 Secure the mirror Instructions Check locking area for signs of wear, remove aluminium chip if necessary. Clip the base of the interior rearview mirror, rotated through 90, into the retainer plate on the windscreen. 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 against the retainer plate with the pliers. The mirror must not be turned past the locking point. Release the pliers from the mirror base.

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Installing the interior rearview mirror

1003

69 53 19 Removing and installing the triggering unit for the airbag

Removing triggering unit for airbag Installing triggering unit for airbag top of page

Removing triggering unit for airbag

WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! Please observe the following points: The airbag ignition unit must not be removed with the plug plugged in! Waiting time following ignition off (battery disconnection) 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 and cover terminal or battery. 3. Unclip front cover of the centre console on the left and right. Fold up the safety bracket from the driver's side.

4. Disconnect the plug connection from the ignition unit.

5. Undo the shearoff nut with a socket wrench insert 9259 . 6. From the passenger's side, undo the shearoff nuts and M6 hexagon nut and remove the ignition unit. top of page

69 53 19 Removing and installing the triggering unit for the airbag

1004

einordnung

Installing triggering unit for airbag

Note The fastening points on the body must be metallically bright! Use a 1/4 inch Allen key to tighten the shearoff 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, 996450, 996451, 996430, 996431, 996840, 996841

Installing triggering unit for airbag

1005

69 54 19 Removing and installing the contact unit

Installing contact unit Installing contact unit top of page

Installing contact unit

1. Remove the airbag steering wheel. 481019 Removing and installing airbag steering wheel

2. Undo and remove the panel.

3. Undo the fastening screws of the contact unit. 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 contact unit locks itself when the steering wheel is pulled back! Likewise, the contact unit unlocks automatically when the steering wheel is refitted!

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Installing contact unit

1. Front wheels still unchanged in straightahead position.

69 54 19 Removing and installing the contact unit

1006

einordnung

2. Ensure that the exact centre position (arrows) of the contact unit is maintained.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Installing contact unit

1007

69 58 19 Removing and installing the driver's airbag unit

Removing driver's airbag unit Installing driver's airbag unit top of page

Removing driver's airbag unit

1. Remove ignition key. 2. Disconnect the battery and cover terminal or battery.

3. Undo the fastening screws (2 ea.) with a socket wrench insert for inside Torx T 30 (at least 50 mm long). Note The selflocking screws must be replaced every time they are undone! To do this, undo the retaining bracket of the airbag 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 following points: The airbag unit must always be deposited 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!

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Installing driver's airbag unit

Tightening torque for fastening screws (2 screws M6 x 16): 10 Nm (7.5 ftlb.) 2. Tightening torque for retaining bracket (3 screws M5 x 20): 5 Nm (3.5 ftlb.)

69 58 19 Removing and installing the driver's airbag unit

1008

einordnung 996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Installing driver's airbag unit

1009

69 59 19 Removing and installing the passenger's airbag unit

Removing passenger's airbag unit Installing passenger s airbag unit top of page

Removing passenger's airbag unit

WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! Please observe the following points: The airbag unit must always be deposited 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 battery and cover terminal or battery. 3. Remove the air guide at the bottom right.

4. Undo the airbag unit from below and remove it rearward to the passenger's seat. 5. Disconnect the electrical plug connection.

6. Pull out the hinge pin on the airbag unit and remove the panel. top of page

69 59 19 Removing and installing the passenger's airbag unit

1010

einordnung

Installing 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

Installing passenger s airbag unit

1011

69 63 19 Removing and installing the side airbag unit

Removing side airbag unit Installing side airbag unit top of page

Removing side airbag unit

WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! Please observe the following points: The airbag unit must always be deposited so that the airbag opening faces upwards! The airbag unit should be placed in a package or packed in film and, if removed for an extended 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 Disassembling and assembling door trim panel Note Behind the "Airbag" inscription lies a screw M5 x 10 that is fastened on the fastening clip of the side airbag unit! The fastening screws must always be replaced after removal! 4. Remove cover with "Airbag" inscription and unscrew the screw. 5. Disconnect electrical plug connection and undo fastening screws.

6. Carefully remove side airbag unit from the door.

69 63 19 Removing and installing the side airbag unit

1012

einordnung

7. Deposit airbag unit correctly. top of page

Installing side airbag unit

Installation of left/right identification of the side airbag unit: Inscription R = Right door Inscription L = Left door Locking pin A must always point to the rear The wire connection point B must always face the front Fastening clip M5 C always to the rear Note The cover film behind the side airbag unit must not be damaged (protects against water leaking in)! 1. Install airbag unit with the inscription "R" in the righthand door and fasten. 2. Engage electrical plug connection. Tightening torque for fastening screws (4 screws M6 x 16): 10 Nm (7.5 ftlb.), (1 screw M5 x 10): 6 Nm (4.5 ftlb.) 3. Reinstall the door trim panel.

Removing sensor for side airbag unit

WARNING Danger of injury and damage to property as a result of incorrect handling of airbag units! Please observe the following points: Removing side airbag unit 1013

einordnung After an accident, the sensor of the triggered side airbag unit must be examined for damage! The sensor must be replaced after the side airbag has been triggered for the third time! Note Sensors for triggering the side airbag unit are fastened on the inner lower side member on the left and righthand sides in the vehicle!

The cover strip and the support on the lower side member must be removed.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Removing sensor for side airbag unit

1014

70 18 19 Removing and installing the instrument panel and instrument panel bracket
Removing and installing the instrument panel Removing and installing the instrument panel bracket Tightening torque Tools and materials

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Removing and installing the instrument panel

70 18 19 Removing and installing the instrument panel and instrument panel bracket

1015

einordnung

Note Before removing the instrument panel, it must be disassembled. => Disassembling the instrument panel

No. Designation 1 Fastening screws

Fastening screws

OnBoard Diagnosis (OBD) socket

Qty. Removal Installation 3 Unscrew fastening screws Screw the instrument panel 4 to the 1 from the instrument instrument panel bracket with the panel 4 . fastening screws 1 . 13 Undo fastening screws 2 Screw the instrument panel 4 to the from the instrument panel instrument panel bracket with the 4 . fastening screws 2 . 1 Unscrew the fastening screws Tighten the fastening screws 2 . 2 . 1016

Removing and installing the instrument panel

einordnung 4 5 6 Instrument panel Sheetmetal nut Instrument panel bracket with knee protector strip Sheetmetal nut 1 2 1 See: Position 1 and 2 See: Position 1 and 2 Unscrew the fastening screws Inspect and replace if necessary. 2 .

11

Unscrew fastening screws 1 Inspect and replace if necessary. and 2 from the instrument panel 4 .

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Removing and installing the instrument panel bracket

Removing and installing the instrument panel bracket

1017

einordnung Note Before removing the instrument panel bracket, the instrument panel must be disassembled. => Removing and installing the instrument panel bracket

No. Designation Qty. Removal 8 Fastening screws 4 9 Threaded plate 4

10 Compensating element

11 Fastening screws 2 12 Instrument panel 1 bracket

13A Closure cap 13B Plug

2 2

14 Sheetmetal clip 4 15 Fastening screws 4 16 USA version, 1 knee protector strip 17 Cowl panel seal 1 18 Adhesive pad 1

Installation => Tightening torque It is screwed into position with the compensating element 10 and the fastening screw 8 . The compensating element 10 By screwing in the fastening screws is released by undoing the 8 , the compensating element 10 fastening screw 18 . can be fixed and secured. => Tightening torque Undo the fastening screws 8 Insert instrument panel bracket 12 into the body. Fix compensating in the compensating elements 10 and guide the instrument elements 10 to the instrument panel bracket and screw down with the panel bracket 12 out of the fastening screws 8 and 11 . body. Pull out. Press in. Only installed on 911 coup versions. Check, if necessary, replace. => Tightening torque Unscrew fastening screw 15 Secure the knee protector strip 16 on the instrument panel bracket 12 and from the knee protector strip tighten the fastening screw 15 . 16 . Remove the knee protector strip. Is destroyed when removed. Tighten protective film. Is destroyed when removed. Attach the adhesive pad for lefthand drives on the right holder and on the left holder for righthand drives.

The bonding area must be free of dust and grease. Tighten protective film and position it. => Tools and materials 19 Clip 4 20 Fastening screws 4 21 Shearoff nut 2 => Tightening torque Undo the shearoff nut with special tool 9259. => Tools and materials 1018

Removing and installing the instrument panel bracket

einordnung 23 Airbag control module 24 Cover panel 1 See: 695319 Removing and See: 695319 Removing and installing installing the triggering unit for the triggering unit for the airbag. the airbag. Fix the cover panel in the body and the instrument panel bracket 12 and screw down with the fastening screws 20 .

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Tightening torque

Tightening torque [Nm] Location Illustration Thread (ftlb.) Apillar 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 strip fastening nuts on the instrument panel 14 M6 10 (7.5) Nm bracket (ftlb.) Knee protector fastening screws on the instrument panel 15 M8 6 (4.5) Nm bracket (ftlb.) Cover panel fastening screws on the instrument panel bracket 20 M6 10 (7.5) Nm (tunnel) (ftlb.)

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Tools and materials

Cutting with adhesive pad X 50 mm Y 40 mm Z 25 mm

Tightening torque

1019

einordnung Punch out the crack Z at a diameter of 7 mm Item 1 2 Special tool designation Socket wrench insert 9259 Adhesive pad, commercially available Teflon adhesive tape Remarks Gr. 2.2; Workshop Equipment Manual Cutting with adhesive pad

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Tools and materials

1020

70 18 37 Disassembling and assembling the instrument panel

Disassembling the instrument panel Assembling the instrument panel Additional assembly notes for the cover and center nozzle for the instrument panel Note The following components; screen, center nozzle and holder have changed on the instrument 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 (model year 2002). 681519 Removing and installing glove compartment 683019 Removing and installing cup holder => Additional assembly notes for the cover and center nozzle for the instrument panel &ndash; as of model year 2002

as of model year 2002

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Disassembling the instrument panel

70 18 37 Disassembling and assembling the instrument panel

1021

einordnung

No.

Procedure Instructions Removing the Apillar 705719 Removing and installing Apillar trim trim Removing the driver's 695819 Removing and installing the driver's airbag airbag Removing passenger's 695919 Removing and installing the passenger's airbag airbag Removing the alarm Lift the alarm readiness cover 3 and unclip it upwards out of the readiness cover and clip 4 . The lens cover 2 can be unclipped for replacement the defroster cover purposes. Lift the defroster covers left and right 5, 6 with a plastic spatula and unclip out of the clips 4 . Removing the alarm Undo the fastening screws 7 , lift the alarm readiness unit 8 and readiness unit disconnect the electrical connection.

Disassembling the instrument panel

1022

einordnung 3 Removing the loudspeaker Removing the instrument mount Undo the fastening screws 9 , raise the outside of the loudspeaker 10 and guide it out. At the plug connection 11 , press the locking tab arrow and disconnect. To remove the hazard warning light switch: switch on the switch 12 (button comes out). There are small openings on the sides which now project over the instrument cowl. Insert two narrow screwdrivers into the openings arrow A and pull off the button towards the front. The hazard warning light 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 towards the front. Press the collar 14 out from the rear. Pull off the cover 15 on the left side and undo the fastening screws 16 . Lift the instrument mount 17 on the left and right and unclip from the clips 4 . Disconnect the electrical connection 18 on the rear side of the instrument mount. To do so, press the locking tab of the plug connection and unlock the locking lever in the direction of the arrow .

Disconnecting the electrical plug connection

Disassembling the instrument panel

1023

einordnung

No. Procedure 6 Removing the side nozzles and the temperature sensor

Instructions Pull off the covering caps 20, 20A . Undo the fastening screws 21 on the side, remove the side nozzle 22 towards the front. Unclip the temperature sensor 24 out of the instrument panel towards the rear. Disconnect the electrical plug connection 23 . Removing left side Pull forward the control button 25 of the light switch 31 as far as it nozzles and main light will go direction of the arrow towards the front. Press in the locking switch device at the lower side using a small screwdriver and remove the control button towards the front. Undo the fastening screws 21 at the side, remove the side nozzle towards the front. Disconnect the plug connection 30 of the main light switch 31 . In order to disassemble the side nozzle, the covering cap 28 , the fastening nut 26 and the inner race 27 of the main light switch 31 can be removed. Remove light switch 31 from the side nozzle by 1024

Disassembling the instrument panel

einordnung turning it slightly in clockwise direction. 8 Removing the steering Undo the fastening screws 32 on the lower steering column switch column switch cover cover 36 and remove both steering column covers 33, 36 or 35 . 9 Removing the steering Undo the fastening screw 37 in the cover 38 and the steering column column switch switch 42 and remove. Disconnect the electrical 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 Removing the steering Undo the fastening screw 43 in the steering column cover 44 and column cover unclip the cover upwards.

No. Procedure 11 Removing the switch cover

Instructions Unclip the switch cover on the left and right 45, 46 towards the front. Disconnect the electrical plug connections of the tip switches. 1025

Disassembling the instrument panel

einordnung 12 Removing the electrical airconditioning and heating regulator variant 47 and the car radio 48, 49 13 Removing display and operator control unit (PCM)50 See: 870219 Removing and installing heating/airconditioning control. See: 912019 Removing and installing the car radio. Press in and hold both spring clips arrow A . Pull out the display and operator control unit 50 . Disconnect the electrical plug connections 51 on the rear side of the display and operator control unit. See: 911019 Removing and installing display and operator control unit (PCM). Raise the retaining clip arrow B of the retaining bracket 52 and guide it out of the cutout of the center nozzle 55 . Pull off the ground cable 53 . Undo the fastening screws 54 and guide the center nozzle 55 out of the instrument panel 1 . Undo the fastening screws 56 from the inside of the retaining bracket 57 . => Additional assembly notes for the cover and center nozzle for the instrument panel &ndash; as of model year 2002 => Removing cover and center nozzle for the instrument panel

14 Removing the PCM retaining bracket

15 Removing the center nozzle

Removing the regulator for wiping interval

1. Disconnect the electrical plug connection. 2. Press the locking tabs of the regulator for the wipe interval arrows A outwards and guide the regulator out of the front cover towards the front.

Removing the cigarette lighter

Removing the regulator for wiping interval

1026

einordnung

1. Disengage the cover arrow A upwards. 2. Press 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

Removing the cigarette lighter

1027

einordnung

No. Procedure Installing the regulator for wipe interval Installing the cigarette lighter 1 Installing the inside retaining bracket and the center nozzle

Instructions => Installing the regulator for wiping interval => Installing the cigarette lighter Position the inside retaining bracket 57 in the instrument panel 1 and 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 instrument panel &ndash; as of model year 2002 => Installing cover and center nozzle for the instrument panel Insert the retaining bracket 52 in the cutout of the center nozzles. Plug the ground cable 53 into the retaining bracket. 1028

Installing the PCM retaining bracket

Assembling the instrument panel

einordnung 3 Connect the electrical plug connection 51 on the rear side of the PCM. See: 911019 Removing and installing display and operator control unit (PCM). Installing the electrical See: 870219 Removing and installing the airconditioning and heating regulator heating/airconditioning regulator. variant 47 and audio See: 912019 Removing and installing the car radio. communication system 48 Installing the switch covers Plug in the electrical plug connections. (Observe the color designation of the wiring harness switches). Check the clips 4 and replace if necessary. Clip in the switch covers 45 and 46 into the center nozzle. Installing the PCM 50

No. Procedure 6

Instructions

Assembling the instrument panel

1029

einordnung Position the steering column cover 44 on the instrument panel and secure with the fastening screws 43 . 7 Connect the electrical plug connection of the steering column switch 42 and position on the steering column. If necessary, install the contact unit 41 . See: 695419 Removing and installing the contact unit. Position the cover 38 on the steering column switch and tighten with the fastening screws 37 . 8 Installing the steering Position the top and bottom steering column switch cover or laterally column switch cover 33, 36, 35 . Using the fastening screws 32 , screw the steering column switch cover at the bottom 36 together with the steering column switch cover at the top 33 . 9 Installing left side Connect the electrical plug connection 30 of the main light switch nozzles and main light 31 . switch Position the inner race 27 in the side nozzle 29 and engage the main light switch in the inner race 27 by turning it slightly counterclockwise. Screw it down with the fastening nut 26 . Tightening torque:3.5 Nm (2.5 ftlb.) Insert the side nozzle into the instrument panel. Secure the side nozzle with the fastening screws 21 . Place the control button 25 on the main light switch. Press the covering cap 28 in. 10 Installing the right side Engage the temperature sensor 24 from the rear into the instrument nozzles and the panel 1 . temperature sensor Insert the side nozzle 22 into the instrument panel 1 . Secure the side nozzle with the fastening screws 21 . Press in the covering caps 20, 20A . Installing the steering column cover Installing the steering column switch

Assembling the instrument panel

1030

einordnung

No. Procedure 11 Connecting instrument cluster electrical plug connection 12 Installing instrument mount

Instructions Plug in the electrical plug connection of the instrument mount. After inserting the plug connection 18 into the instrument mount, lock it in the direction of the arrow . Install the hazard warning light switch 13 and the collar 14 . Plug in the hazard warning light switch electrical plug connection. Insert 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 of the cover 17 and engage the microphone in the cutout of the instrument mount. 13 Installing the loudspeaker Connect electrical plug connection 11 . Insert the loudspeaker in the instrument panel and secure with the fastening screws 9 . 14 Installing the alarm Connect the plug connection. Secure the alarm readiness unit 8 with readiness unit the fastening screws 7 . Assembling the instrument panel 1031

einordnung 15 Installing the alarm readiness cover and the defroster cover Clip the defroster covers on the left and right 5, 6 into the clips 4 . Clip the alarm readiness cover 3 above the alarm readiness unit 8 into the clips 4 .

Installing the regulator for wiping interval

1. Insert the regulator for 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 ring with the cigarette lighter C into the front cover from the front. 2. Clip the lights bracket B into place. Ensure that the locking tabs have engaged. 3. Clip in the cover A . Ensure that the locking tabs have engaged. top of page

Installing the regulator for wiping interval

1032

einordnung

Additional assembly notes for the cover and center nozzle for the instrument panel as of model year 2002

Removing cover and center nozzle for the instrument panel

1. Removing cover and center nozzle a. Insert a plastic spatula into the side 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 simultaneously pull out the center nozzle 2 with the cover 1 .

2. Removing frame Unscrew fastening screws 3 from the frame 4 .

Additional assembly notes for the cover and center nozzle for the instrument panel

as of model 1033 year 2002

einordnung

3. Unclipping the cover from the center nozzle Push 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

Removing cover and center nozzle for the instrument panel

1034

einordnung

1. Installing holder Position the holder A on the instrument panel and secure with the fastening screws 1 .

Installing cover and center nozzle for the instrument panel

CAUTION Danger of material damage to finished covers! The control 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 (carbonfibre composite, light/dark wood) could be damaged as a result.

1. Clipping in the center nozzle Connect the cover 1 with the center nozzle 2 . Ensure that the locking tab is engaged on the left and right side.

Installing holder

1035

einordnung

2. Installing frame a. Position the frame 5 on the instrument panel and secure with the fastening screws 3 .

3. Installing 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, 996451, 996840, 996841, 996430, 996431

Installing cover and center nozzle for the instrument panel

1036

70 22 19 Removing and installing cowl panel cover

Removing and installing cowl panel cover

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Removing and installing cowl panel cover

70 22 19 Removing and installing cowl panel cover

1037

einordnung

No. Designation 1 Twist lock 2 Battery cover 3 Torx screw T25 M5 x 30 4 Radiator tank cover, right 5 Radiator tank cover, left 6 Dummy pressin nut 7 Cam 8 Cap 9 T5 plastic nut

Qty. Removal 2 1 2 1 1 2 2 2 2 Unclip Position and press in

Installation

Clip in With a small screwdriver Check, replace if necessary 1038

Removing and installing cowl panel cover

einordnung 10 Torx screw T20 x 20 11 Cover 12 Nut Left wiper arm Right wiper arm Cowl panel cover Sheetmetal nut B4.8 17 Electrical plug connection 19 Spray nozzle 13 14 15 16 3 1 2 1 1 1 3 2 2

Undo

Tightening torque: 17 Nm (13 ftlb.)

Adjust to centre of hole. Press locking tabs together and separate electrical plug connection. Use a screwdriver to lift the spray nozzle at the front edge. Pull off water hose. Twist and pull off. Remove filter element. Connect electrical plug connection. Push on water hose and press spray nozzle into the cowl panel cover. Clean filter element if necessary.

19 Tpiece (filter element)

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Removing and installing cowl panel cover

1039

70 59 19 Removing and installing door trim panel

Removing 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

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Removing door trim panel

70 59 19 Removing and installing door trim panel

1040

einordnung

WARNING Airbag could inflate. Danger of injury or damage during fitting! 1. Remove ignition key. 2. Disconnect and cover the negative terminal of the battery. 3. After the battery is disconnected, 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 piece of the cover for protection during transport and assembly. Pull the hook out of the end piece only after installation in the inner door release.

Removing door trim panel

1041

einordnung

No. Procedure 1 Removing 1 cover

6 7 8

Instructions Use a plastic spatula to release the clipped connection out of the door handle on all sides. Unscrew the fastening screws 2, 3, 4 . Removing plastic cover Press the cover out with a narrow screwdriver 5 . Unscrew the (airbag) fastening screw seated below it. Press light 7 out of the door trim panel using a plastic spatula 10 . Disconnect (pull off) electrical plug connection. Disconnect bowden cable Disconnect electrical plug connection from the microswitch for the and electrical plug door handle 9 and orientation lighting 10 . connection Press 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 . Removing door trim panel Unscrew expanding nut from the door trim panel. Unclip door trim panel out of the door on all sides and lift up and off. Clips 13, 14 must be replaced for assembly. Removing airbag Disconnect electrical plug connection 15 . Unscrew fastening screws 16 out of the side airbag 17 and remove. Removing frame Unscrew fastening screws 18 from the mount 19 . Removing door sealing Pull off carefully on all sides. film Removing sound box Disconnect electrical plug connection from the sound box 21 . Unscrew fastening screws 22 from the sound box 23 .

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Installing door trim panel

Installing door trim panel

1042

einordnung

CAUTION Water may enter at the door film! Door films which have become completely detached or are torn must always be replaced. In the case of door films which have become partly detached at the top and side, the detached films must be reattached using a butyl sealing cord.

No. Procedure 1 Installing sound box

Instructions Position sound box 23 in the door. Screw on the sound box with the fastening screws 22 . Connect electrical connection 21 . Affixing door sealing Peel off protective film A on the door sealing film and position on the film. door. Using a roller B , press on the door film on all sides 20 . Attach the old door sealing film: 1043

Installing door trim panel

einordnung => Notes on the installation of partly detached door sealing films Installing frame Position the frame 19 on the sound box. Make sure that the door sealing film cutout is positioned correctly on the sound box. Screw in fastening screws 18 and tighten. Installing side airbag Position side airbag 17 on the door and tighten fastening screws 16 . Tightening torque:10 Nm (7.5 ftlb.) The fastening screws 16 must be replaced each time they are undone. Engaging bowden Engage bowden cable 7 in the door handle. Pull the hook out of the end cable. piece of the sleeve only after installation in the door handle. Clip plastic Connecting electrical clip into the door handle. plug connection. Connect electrical plug connections 8, 9 . Installing door trim The clips 13, 14 must be replaced every time the door trim panel is panel removed. Position the door trim panel on the door and clip it in. Installing the airbag Position fastening screws 5 in the door trim panel and tighten. plastic cover => Tightening torque Press in plastic cover. Make sure the logo reads correctly. Installing cover Screw in the fastening screws 2, 3, 4 and tighten. Clip in the cover 1 on the door handle.

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Installation note for door sealing film

Installation note on door sealing film for vehicles without side airbag

The spare door sealing film comes with 4 holes for fastening the side airbag. For vehicles without airbag, the holes in the door sealing film 2 must be covered with commercially available adhesive tape 1

Notes on the installation of partly detached door sealing films

Door sealing films which have become completely detached or are torn must always be replaced.

Installation note for door sealing film

1044

einordnung

In the case of door sealing films which have become partly detached at the top and side, the detached films must be reattached using a butyl sealing cord. Beside the original point of attachment, attach a butyl cord 2 to the area where the door sealing film 1 is detached, and firmly affix. => Materials and tools top of 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 sliding strip onto the front of the inner door panel Remove backing film from the sliding strip and stick the strip onto the front of the inner door panel arrow . Start at the top (top edge of inner door panel) and follow the curvature.

Notes on the installation of partly detached door sealing films

1045

einordnung

1. Sticking sliding strip onto the rear of the inner door panel Remove backing film from the sliding strip and stick the strip onto the rear of the inner door panel arrow . Start at the top (top edge of inner door panel) and follow the curvature. top of page

Materials and tools

Item 1

Designation of the special tool Remarks Butyl sealing cord to reaffix the Spare parts Gr. 8 07/10; Parts Catalogue door film

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Tightening torque

Location Fastening screws on door trim panel on the doors

Tightening Illustration Thread torque Procedure 7, Item 5 M6 5.9 (4.4) Nm (ftlb.)

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Fitting sliding strip on the inner door panel

1046

70 65 19 Removing and installing oddments compartment lid

Removing and installing oddments compartment lid

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Removing and installing oddments compartment lid

70 65 19 Removing and installing oddments compartment lid

1047

einordnung

No. Designation 1 Door trim panel 2 Snap ring 11 x 1 3 Shaft

Qty. Removal 1 1 Remove the snap ring 2 with a snap ring pliers. Pull the shaft 3 out of the guide mechanism 6 and the lid 4 . To remove lid for oddments compartment 4 , see: (Item 3)

Installation Put the snap ring onto the shaft with a snap ring pliers 3 . Position lid 4 in the door panel 1 and guide mechanism 6 , and push in shaft 3 until it engages at the groove.

Lid for oddments 1 compartment Ovalhead screw 2 4.2 x 14 Guide mechanism 1

5 6

Undo sheetmetal screws 5 Position the guide mechanism 6 on the B 4.2 x 14 on the rear side of rear side of the door panel and tighten with the door trim panel. the sheetmetal screws 5 1048

Removing and installing oddments compartment lid

einordnung B 4.2 x 14.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Removing and installing oddments compartment lid

1049

70 84 19 Removing and installing roof lining

Removing roof lining Installing roof lining

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Removing roof lining

70 84 19 Removing and installing roof lining

1050

einordnung

Note Before removing the roof lining, the => Removing and installing trim of A, B and Cpillars and 6040 Removing and installing sliding roof panel must be removed!

No. 1

Procedure Remove interior light cover

Instructions Using a small screwdriver, carefully unclip both cover 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 the electrical plug connection of the sliding roof rocker switch and the interior light Remove sun visors 6823 Removing and installing sun visors and brackets Insert a small screwdriver into the slot in the cover of the sun visor 1051

Removing roof lining

einordnung console and press out. Undo the crossrecess screw seated below it and remove. Unclip front plastic Undo the Torx screws M6 x 25 in the plastic lining at the front and lining unclip the lining out of the cowl panel frame in a downward direction at the left and right. Detach roof liner at Unclip the metal strut of the roof liner from the plastic clips at the right sides and left. Disengage rear Pull the rear plastic lining towards the rear out of the roof frame evenly plastic lining on the left and right and disengage. Disengage the Pull the metal brace contained in the fabric pocket down in the centre so metal strut that it bends. Pull the metal strut out of the bracket on the left and right. Disengage frame Pull the frame of the sliding roof cutout backwards and downwards in the centre at the front, so that the frame overlap at the corners is reduced and it is possible to pull it out in a downward direction. Then pull out the roof frame diagonally via the sliding roof cutout inwards into the passenger compartment.

4 5 6 7

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Installing roof lining

Installing roof lining

1052

einordnung

No. 1

3 4 5

Instructions Note: Before installing the roof lining, carry out a visual inspection of the rear plastic lining to check that the Styrofoam cover and the selfadhesive fabric parts on the locking peg are completely seated. Fit frame Insert the roof frame diagonally from the inside via the sliding roof cutout of the passenger compartment. At the same time, pull the frame backwards in the centre at the front of the sliding roof cutout, so that the frame overlap at the corners is reduced and it is possible to insert the frame into the sliding roof cutout. Disengage the Pull the metal brace contained in the fabric pocket down in the centre so metal strut that it bends. Pull the metal strut out of the bracket on the left and right. Engage rear plastic Engage the rear plastic lining towards the rear into the roof frame evenly lining on the left and right.

Procedure Check roof lining

Installing roof lining

1053

einordnung Engage roof liner at sides Clip in plastic lining at front Install brackets and sun visors Remove interior light cover Engage the metal strut of the roof liner into the plastic clips at the left and right. Position the front plastic lining at the left and right on the cowl panel frame and clip in. Tighten the Torx screws M6 x 25. Position the bracket on the cowl panel frame, screw in crossrecess screw. Press in the cover of the bracket until it engages. 6823 Removing and installing sun visors Connect the electrical plug connection of the sliding roof rocker switch and the interior light. Position the cover at the front on the windscreen, push backwards and clip in at the left and right arrow B . Position crossrecess screws M5 arrow A and tighten. Carefully clip both cover lenses into the openings provided.

6 7

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Installing roof lining

1054

80 23 19 Removing and installing heat exchanger

Removing heat exchanger Installing heat exchanger top of page

Removing heat exchanger

1. Remove the covers over the heating/airconditioning system, battery and fluid tank. 2. Disconnect the battery and cover terminal or battery. 3. Remove the entire wiper link with wiper motor. 921519 Removing and installing wiper motor.

4. Loosen right dome strut and bracket at the cowl frame and remove (arrows) . 5. Clamp shut both heater hoses in front of the heat exchanger 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 up and out. top of page

Installing heat exchanger

1. Seal cover over the heat exchanger airtight with butyl adhesive. 2. Replace cover if damaged. 3. The heat exchanger is connected to the engine cooling system, and coolant flows through it when the engine is running. After removing or installing the heat exchanger, vent the cooling system. 193817 Draining and filling in coolant

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 80 23 19 Removing and installing heat exchanger 1055

85 30 19 Removing and installing heater/freshair blower motor

Removing heater/freshair blower motor Installing heater/freshair blower motor top of page

Removing heater/freshair blower motor

Note Remove and install heater/freshair blower motor with installed heating/freshair unit! 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 resistor and undo both fastening screws on the housing lid (arrows) . The ballast resistor and housing lid are one spare part. Note When the housing lid is removed, the blower motor is simultaneously detached from its guide!

85 30 19 Removing and installing heater/freshair blower motor

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einordnung

4. Hold the blower motor and carefully remove it in downward direction. top of page

Installing heater/freshair 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, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing heater/freshair blower motor

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87 01 19 Removing and installing the heating/airconditioning unit

Removing heating/airconditioning unit Installing heating/airconditioning unit top of page

Removing heating/airconditioning unit

1. Remove the covers over the heating/airconditioning system, battery and fluid tank. 2. Disconnect and remove the battery. 3. Remove the refrigerant by suction using the service unit. 4. Detach the airconditioning lines at the expansion valve. Immediately close connections and lines with plugs so that they are airtight. 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 waiting period of at least 1 minute has elapsed! 5. Remove steering wheel and loosen steeringcolumn panel.

6. Undo the central screw (clamp) on the steering column switch from below and pull it forwards slightly. Remove the cover at the top and disconnect the electrical plug connections. Remove the steering column switch.

7. Loosen instrument panel and unclip right side upwards. 8. Disconnect the electrical plug connections.

87 01 19 Removing and installing the heating/airconditioning unit

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einordnung

9. Remove steeringcolumn cover (4 screws).

10. Remove the radio and heating/airconditioning controller. Unclip the switch panel on the left and on the right. Disconnect the electrical plug connections. Undo the retaining frame in the centre and remove. 11. Remove left side nozzle and disconnect electrical plug connection. 12. Unclip cover of sun sensor and defroster panel and remove. 13. Undo the passenger compartment monitoring and disconnect the electrical plug connection. 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 waiting period of at least 1 minute has elapsed! 14. Remove the air guide at the bottom right. 15. Remove the passenger's airbag unit. 16. Remove the front cover of the centre console. 17. Undo the fuse holder and data link connector in the left footwell.

18. Loosen dashboard on the bottom, centre, left and right. 19. Carefully remove the dashboard and detach the loudspeaker cable. 20. Loosen centre tunnel support at the top of supporting frame and loosen bottom tunnel holder. 21. Remove the left air guide. Only loosen the defrost channel. Undo and remove the centre air distributor casing. Removing heating/airconditioning unit 1059

einordnung 22. Disconnect the central plug connections (2 ea.) from the heater/airconditioning unit.

23. Loosen battery positive connection at the current distributor and current distributor arrows at the firewall cover. 24. Clamp shut both heater hoses in front of the heat exchanger with a commercially available hose clamp. Disconnect the heating hoses on the heat exchanger and plug the connections. 25. Undo heater/airconditioning unit on the firewall cover (3 nuts). Pull off the water drainage hose from the heater/airconditioning unit.

26. Undo holder of the heater/airconditioning unit from the passenger's side at the top right arrow . 27. Carefully lower the heater/airconditioning unit downwards into the footwell and remove. Do not damage the electrical plug connections or cables. top of page

Installing heating/airconditioning unit

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 waiting period of at least 1 minute has elapsed! 1. Ensure that the air distributor casing and air guides are correctly positioned. Engage the electrical plug connections and carefully lay the electrical cables (do not pinch).

Installing heating/airconditioning unit

1060

einordnung 2. Set the steering column switch: Measure with a depth gauge between end of steering shaft and steeringcolumn switch cover plate. Adjustment dimension: 55 0.5 mm 3. Replace gasket between current distributor and firewall if necessary. 4. After the current distributor is mounted on the firewall, the battery cable is tightened with a new hexagon nut M8. Tightening torque: 15 Nm (11 ftlb.) Note If the heating/airconditioning unit is replaced, the refrigerant oil in the evaporator must be topped up! Refrigerant oil removed from a previously run airconditioning system may no longer be used (specialcategory waste)! 5. Replace the rings for the refrigerant lines at the expansion valve and wet the new rings with refrigerant oil. 6. Determine the quantity of the refrigerant oil and fill up again with refrigerant oil (volume removed by suction + 20 cm3 ). 7. The heat exchanger is connected to the engine cooling system, and coolant flows through it when the engine is running. After removing or installing the heater/airconditioning unit, bleed the cooling system 193817 Draining and filling in coolant.

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Installing heating/airconditioning unit

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87 02 19 Removing and installing the heating/airconditioning control

Removing heating/airconditioning control Performing system test Tests top of page

Removing heating/airconditioning control

Note Basic adaptation to the system must be performed with a new heating/airconditioning control! This is indicated by flashing of the displays for approx. 5 to 10 seconds each time the ignition is switched on! Basic adaptation is performed during the system test! 1. Unclip cover.

2. Unscrew fastening screws (2 ea.) and pull the heating/airconditioning control out of the dashboard. 3. Disconnect the electrical plug connections. top of page

Performing system test

1. Connect and switch on the Porsche System Tester 2. 2. Select air conditioning and menu item "System test" The following conditions must be observed for the system test: Vehicle speed < 10 km/h Engine start detected and 10 seconds elapsed since engine start Terminal 15 supply voltage OK 5volt supply voltage OK Engine temperature < 110 C Outside temperature > 3 C 87 02 19 Removing and installing the heating/airconditioning control 1062

einordnung

top of page

Tests
Display of all segments in the control module. The drive motors are traversed across the entire range once. The measured positioning travel is subjected to a plausibility test and stored as a fault if necessary. Two different voltage values are set on the freshair blower and tested. The A/C circuit is tested via the DME. All fault paths are tested, and any faults are stored. Basic adaptation is carried out after the system test has been completed. The display must no longer flash.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Performing system test

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87 03 17 Assembly work on the airconditioning system

Service unit SECU 134 Assembly work involving the refrigerant system General assembly sequence Removing refrigerant by suction and cleaning Cleaning the refrigerant Draining off old refrigerant oil Evacuating Topping up with new refrigerant oil Filling via the highpressure side Refilling the airconditioning system Distribution of the oil quantity in the refrigerant circuit top of page

Service unit SECU 134

Note The manufacturer's operating and repair instructions must be observed when carrying out all work on the service unit!

87 03 17 Assembly work on the airconditioning system

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einordnung

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Lowpressure pressure gauge Highpressure pressure gauge Torr meter Lowpressure shutoff valve (blue) Highpressure shutoff valve (red) Torr meter shutoff valve (black) Vacuum pump shutoff valve (yellow) Lowpressure flange Highpressure flange Refrigerant inlet shutoff valve Refrigerant outlet shutoff valve Refrigerant oil inlet shutoff valve Refrigerant oil vent valve Moisture indicator 1065

Service unit SECU 134

einordnung 15 16 17 18 19 20 21 22 23 24 25 26 27 Oil tank vacuum flange Hourmeter SUCTION/END indicator light SUCTION/CLEAN pressure switch ON/OFF main switch HEATING pressure switch MALFUNCTION indicator light VACUUM PUMP pressure switch Filling cylinder with weight scale Filling cylinder shutoff valve Filling cylinder highpressure gauge Refrigerant oil suction nozzle Refrigerant oil reservoir inspection glass

top of page

Assembly work involving the refrigerant system

Note The safety regulations must be observed during all work on the refrigerant system! => Safety regulations when handling refrigerant R134a During all work on the airconditioning system which necessitates opening the refrigerant system, the system contents must first be disposed of correctly! Dirt and moisture must be kept out of the airconditioning system's pipe system! Thorough cleanliness must be ensured during all work! System components must never be cleaned on the inside with hot steam! Use only nitrogen for cleaning purposes! When replacing a component, all openings must be closed off with suitable plugs!

top of page

General assembly sequence

Note Pay attention to sealing rings when disconnecting or connecting the hose connections! The charging valves are located in the area of the front right spring strut.

Assembly work involving the refrigerant system

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einordnung

A = high pressure B = low pressure 1. Remove refrigerant by suction. 2. Remove faulty 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 valves before carrying out each work step!

General assembly sequence

1067

einordnung A 1 2 Close Suction removal, start ON/OFF SUCTION/CLEAN B 3 4 Open End SUCTION/END ON/OFF

* Pressure too high/filling cylinder full. Drain off refrigerant from the filling cylinder into a refrigerant bottle (approx. 50%). top of page

Cleaning the refrigerant

A 1 2

Close Cleaning, start ON/OFF SUCTION/CLEAN

B 3 4

Open End CLEAN/END ON/OFF

* Pressure too high/filling cylinder full. ** One revolution OPEN. After approx. 15 minutes CLOSED. top of page

Draining off old refrigerant oil

Removing refrigerant by suction and cleaning

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einordnung

A 1

Close ON/OFF

Open

Instructions: *1 open to *2 OFF, then *1 CLOSED and *3 OPEN. top of page

Evacuating

A 1

Close ON/OFF

Open

Draining off old refrigerant oil

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einordnung 2 VACUUM PUMP

Evacuation time at least 15 minutes. top of page

Topping up with new refrigerant oil

A 1

Close ON/OFF

Open

top of page

Filling via the highpressure side

Evacuating

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einordnung

A 1 2

Close ON/OFF HEATING

Open

* Pressure 8 ... 10 bar. ** If pressure is less than 8 bar. Note Before carrying out internal suction removal of the SECU, the hand valves on both suction lines must be closed! After using the SECU, perform internal suction removal. top of page

Refilling the airconditioning 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 suction using the service unit 2. Determine the refrigerant oil quantity after the refrigerant has been removed by suction. 3. Fill up with new refrigerant oil. 4. Evacuate. 5. Fill with the stipulated amount of refrigerant. 6. Check the system for leaks. Filling via the highpressure side 1071

einordnung top of page

Distribution of the oil quantity in the refrigerant circuit

Note Oil removed by suction must be returned to the system! Refrigerant oil removed from a previously run airconditioning system may no longer be used (specialcategory waste)! After the refrigerant has been removed by suction and a component has been replaced, the 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 quantities remain in the: Condenser (2 x 20 cm3 ) approx. 40 cm3 Evaporator approx. 30 cm3 Fluid tank with lines approx. 30 cm3 Compressor approx. 50 cm3 Circulating oil quantity in the refrigerant circuit approx. 60 cm3

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Refilling the airconditioning system

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87 20 19 Removing and installing drive motors

Note Removing drive motors Installing drive motors Note Removal or installation is performed with the heating/airconditioning unit installed!

top of page

Removing drive motors

Removing drive motor for temperature 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 vent (3 screws) . 2. Press pivot pin on the adjusting lever together and disengage the deflection lever. 3. Unscrew drive motor of the heating/airconditioning unit and disconnect the electrical plug connection.

87 20 19 Removing and installing drive motors

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einordnung

Removing drive motor for footwell/defrost

1. Unscrew drive motor with bracket from the heating/airconditioning unit (2 screws) . 2. Swivel drive motor to the side and disengage the deflection lever. 3. Disconnect electrical plug connection and detach bracket from the drive motor.

Removing drive motor for freshair/recirculation valve

1. In order to block the freshair supply, the Recirculation button must be pressed before removal. The drive motor can be removed from the installed heating/airconditioning 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.

4. Disengage pivot pin on the adjusting lever with a screwdriver. 5. Swivel down the drive motor and remove it to the side. top of page

Installing drive motors

Installing drive motor for temperature valve, central valve and footwell/defrost
1. Ensure that the deflection levers are seated correctly. 2. Tighten fastening screws carefully (plastic housing). 3. Engage electrical plug connections and route wire carefully. Removing drive motor for footwell/defrost 1074

einordnung 4. Perform function test after installation of the drive motors.

Installing drive motor for freshair/recirculation valve

Note The removal or installation position of the drive motor and freshair/recirculation valve cannot be changed! Ensure that the deflection lever of the outsideair valve is seated correctly! 1. Tighten fastening screw carefully (plastic housing). 2. Engage electrical plug connection and route wire carefully. 3. Perform a function test after installation.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing drive motor for temperature valve, central valve andfootwell/defrost

1075

87 27 19 Removing and installing the magnetic coupling

Removing the magnetic coupling Installing the magnetic coupling top of page

Removing the magnetic coupling

1. Use a standard strap wrench to securely hold the pressure plate, and undo the fastening screw. 2. Screw a screw M8 into the thread of the pressure plate until the pressure 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 magnetic coil from the compressor housing. 6. Remove the Seeger circlip ring. 7. Remove the magnetic coil from the compressor housing. top of page

Installing the magnetic coupling

1. Place the magnetic coil on the compressor housing (the locking pin must engage in the locking hole).

87 27 19 Removing and installing the magnetic coupling

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einordnung

2. Install the Seeger circlip ring. The slanted surface of the Seeger circlip ring faces upwards (to the fastening screw). 3. Tighten the pressure plate fastening screw. Tightening torque: 14 Nm (10.5 ftlb.)

Checking the air gap of the magnet coupling

1. Check the air gap between the pressure plate and belt pulley with a depth gauge. 2. Place a rule on the 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 mm 0.15 mm 3. Apply battery voltage to the magnetic coupling and measure the distance (air gap) to the attracted pressure plate. 4. If the air gap is not in the tolerance range, it must be adjusted with the aid of the spacer washers.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing the magnetic coupling

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87 34 19 Removing and installing the compressor

Removing the compressor Installing the compressor top of page

Removing the compressor

1. Remove the cover above the heating/airconditioning system. 2. Remove the refrigerant by suction using the service unit. 3. Disconnect the battery and cover terminal or battery. Remove the complete air cleaner assembly. Undo the fastening screw for the air cleaner housing and the hose clamp on the air flow sensor. 4. Undo the hose on the charge air cooler at the left and right on the pressure pipe. 5. Disconnect the electrical plug connection on the air flow sensor and remove the 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 tensioning pulley and remove the belt. 8. Remove belt pulley for hydraulic pump. 9. Undo fastening screws on the expansion tank (2 M8 screws) and the hydraulic pump (3 M8 screws and one M6). Leave aside expansion tank with hydraulic pump and connected lines. 10. Undo the fuel supply lines on the fuel cooler. Make sure to counter when doing this.

11. Remove throttle body. 12. Disconnect electrical plug connection for compressor.

13. Undo the compressor from the console (3 screws). 14. Lift the compressor with fastening screws out of the bracket and carefully remove to the rear.

87 34 19 Removing and installing the compressor

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einordnung Note The hydraulic pump with expansion tank must be lifted slightly upwards when doing this! 15. Undo the refrigerant lines at the compressor. Immediately close connections and lines with plugs so that they are airtight. top of page

Installing the compressor

Note New compressors are pressurised and are filled with the required amount of oil for the refrigerant circuit! The remaining oil quantity in the individual components must therefore be taken into account! Refrigerant oil from the compressor or refrigerant oil removed by suction from a previously run airconditioning system may no longer be used (specialcategory waste)! 1. First, open the cap on the highpressure side and relieve the pressure from the compressor A .

2. Open the oil filler screw B on the compressor. 3. 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. Tightening torque for oil filler plug M10 x 1: 26 to 36 Nm (19 to 27 ftlb.) 5. Use fastening screws from the new compressor. Replace Orings and wet the new rings with refrigerant oil. Tightening torque for refrigerant line, screws M8 x 32: 23 Nm (17 ftlb.) 6. Do not remove the plugs for the lines and compressor connection until shortly before installation. 7. Install compressor with lines. 8. Engage electrical connection and install compressor with fastening screws. 9. Install expansion tank with hydraulic pump. Tightening torque for the compressor fastening screws on the console, M8 screws: 23 Nm (17 ftlb.) Tightening torques of the fastening screws for the belt pulley and hydraulic pump expansion tank: M8 screws: 23 Nm (17 ftlb.) M6 screw: 10 Nm (7.5 ftlb.) Removing the compressor 1079

einordnung 10. Mount belt pulley for hydraulic pump and fit drive belt. 11. Install throttle body and engage frequency valve. 12. Fasten the fuel supply lines on the fuel cooler. Make sure to counter when doing this. 13. Install the pressure pipe to the throttle body and air cleaner assembly. 14. Secure the hose on the left and right on the pressure pipe. 15. Connect the battery. 16. Fill the heating/airconditioning system with refrigerant.

Runningin regulations for new compressor

Note Fill the airconditioning system (fluid) via the highpressure 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 idle speed to stabilise (approx. 5 seconds). 3. Set the fan to max. output. 4. Switch on the airconditioning system AC switch and allow it to run uninterrupted for at least 2 minutes at 1500 rpm. 5. After 2 minutes uninterrupted compressor operation time, the oil distribution in the airconditioning system is completed and the compressor can be run up to the max. engine speed.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing the compressor

1080

87 50 19 Removing and installing the condenser

Removing the condenser Installing the condenser top of page

Removing the condenser

1. Remove the cover above the heating/airconditioning system. 2. Remove the refrigerant by suction using the service unit. 3. Completely remove the front spoiler. Remove the air guide to the condenser and pull off the electrical plug connection on the temperature sensor. 4. Undo the refrigerant line on the condenser. Immediately close connections and lines with plugs so that they are airtight.

5. Undo the fastening screws from the condenser and pull the condenser to the side out of the holder. top of page

Installing the condenser

Note Refrigerant oil removed from a previously run airconditioning system may no longer be used (specialcategory waste)! 1. Do not remove the plugs for the lines and condenser connection until shortly before installation. 2. Replace Orings and wet the new rings with refrigerant oil. Note When loosening or tightening the M8 refrigerant lines on the condenser, always counter with a 21 mm openended wrench! Tightening torque for M8 refrigerant lines: 14 Nm (10.5 ftlb.) Tightening torque for condenser: 4.0 0.5 Nm (3.0 0.5 ftlb.) Tigthening torque for air guide: 4.0 0.5 Nm (3.0 0.5 ftlb.) 3. Determine the quantity of the refrigerant oil and fill up again with refrigerant oil (volume removed by suction + 20 cm3 ) 87 50 19 Removing and installing the condenser 1081

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing the condenser

1082

87 53 19 Removing and installing fan for condenser

Removing fan for condenser Installing fan for condenser top of page

Removing fan for condenser

1. Remove front wheel, front wheel housing liner and front spoiler. 2. Detach cooler bracket from the body (1 nut, 2 M8 screws and 1 sheetmetal screw) .

3. Undo retaining clips from the radiator and pull 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 motor and ballast resistor from the fan housing and remove. top of page

Installing fan for condenser

1. After installation, check whether the fan can rotate freely. 2. Tighten front wheel. Tightening torque: 130 Nm (96 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

87 53 19 Removing and installing fan for condenser

1083

87 55 19 Removing and installing the fluid tank

Removing fluid tank Installing fluid tank top of page

Removing fluid tank

1. Remove the cover above the heating/airconditioning system and fluid tank. 2. Remove the refrigerant by suction using the service unit.

3. Undo the hose clamp on the fluid tank. Undo both hexagonhead bolts on the fluid tank and remove the fluid tank upwards. Immediately close lines with plugs so that they are airtight. top of page

Installing fluid tank

Note The fluid tank must be replaced if the system suffers from operational faults (e.g. accident damage or airconditioning system depressurised)! Used refrigerant oil extracted from a previously run A/C unit must not be reused! 1. Do not remove plugs until shortly before installation. Replace the Oring on the branch piece and on the refrigerant line, and wet the new Orings with refrigerant oil. 2. Tighten both hexagonhead bolts on the fluid tank. Tightening torque: 6 Nm (4.5 ftlb.) 3. Determine the quantity of the refrigerant oil and fill up again with refrigerant oil (volume removed by suction +30 cm3 ).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

87 55 19 Removing and installing the fluid tank

1084

87 58 19 Removing and installing footwell blower outlet sensor

Removing footwell blower outlet sensor Installing footwell blower outlet sensor top of page

Removing footwell blower outlet sensor

1. Remove footwell bulkhead. 2. Unclip centre console cover at the front and remove the footwell 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 temperature sensor on the heating/airconditioning unit housing and turn by 90 (tighten). 2. Engage electrical plug connection and route wire carefully.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

87 58 19 Removing and installing footwell blower outlet sensor

1085

87 59 19 Removing and installing outside temperature sensor

Removing outside temperature sensor Installing outside temperature sensor top of page

Removing outside temperature sensor

Note Removing and installing outside temperature sensor on the installed heating/airconditioning unit! 1. Remove footwell bulkhead and right air guide. 2. Remove drive motor for freshair/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 sensor

1. Place temperature sensor on the intake duct and turn by 90 (tighten). 2. Engage electrical plug connection and route wire carefully. 3. Install drive motor for freshair/recirculation valve and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

87 59 19 Removing and installing outside temperature sensor

1086

87 70 19 Removing and installing the expansion valve

Removing expansion valve Installing expansion valve top of page

Removing expansion valve

1. Remove the cover above the heating/airconditioning system. 2. Remove the refrigerant by suction using the service unit. 3. Detach the airconditioning lines at the expansion valve. Immediately close connections and lines with plugs so that they are airtight.

4. Undo the expansion valve arrow and remove. Immediately close the lines to the evaporator with plugs so that they are airtight. top of page

Installing expansion valve

Note Refrigerant oil removed from a previously run airconditioning system may no longer be used (specialcategory waste)! Do not remove plugs until shortly before installation. Replace Orings and wet the new rings with refrigerant oil. Tightening torques: M5 screw: 6 Nm (4.5 ftlb.), M6 screw: 9 Nm (6.5 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

87 70 19 Removing and installing the expansion valve

1087

87 78 19 Removing and installing blower driver

Removing blower driver Installing blower driver top of page

Removing blower driver

1. Remove footwell bulkhead and right air guide.

2. Unscrew fastening screw and detach the blower driver from the heating/airconditioning unit housing from below. 3. Pull blower driver 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 driver into the upper bracket. 2. Tighten fastening screw carefully (plastic housing). 3. Install the air guide and footwell bulkhead. 4. Perform function test on heater/freshair blower motor.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

87 78 19 Removing and installing blower driver

1088

87 82 19 Removing and installing interior temperature sensor

Removing interior temperature sensor Installing interior temperature sensor top of page

Removing interior temperature sensor

1. Pull off cover for temperature sensor. 2. Undo three Torx screws of the right side vent and carefully pull the side vent out of the dashboard. One Torx screw 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 sensor

1. Engage electrical plug connection, ensuring that the temperature sensor is seated properly in the dashboard. 2. The cover simultaneously serves as the intake grille for the fan and must not be closed off.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

87 82 19 Removing and installing interior temperature sensor

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87 83 19 Removing and installing pressure switch for the airconditioning system

Removing pressure switch for the airconditioning system Installing pressure switch for the airconditioning system top of page

Removing pressure switch for the airconditioning system

1. Remove the cover above the heating/airconditioning system. 2. Remove the refrigerant by suction using 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 airconditioning system

Note Refrigerant oil removed from a previously run airconditioning system may no longer be used (specialcategory waste)! Replace the Oring on the pressure switch and wet it with refrigerant oil. Tightening torque: 3 Nm (2 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

87 83 19 Removing and installing pressure switch for the airconditioning system

1090

90 12 15 Setting ahead the total mileage counter in the instrument cluster

Setting ahead with the Porsche System Tester 2 top of page

Setting ahead with the Porsche System Tester 2

Note The kilometre reading must be set ahead after replacement of the instrument 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 kilometre reading 8. Code with F8 key The total mileage is adopted in the new instrument cluster after coding.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

90 12 15 Setting ahead the total mileage counter in the instrument cluster

1091

90 25 37 Disassembling and assembling instrument cluster

Note Note The 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, 996651

90 25 37 Disassembling and assembling instrument cluster

1092

90 50 19 Removing and installing horn

Note Removing horn Installing horn Note Both horns are fastened on a bracket on the right front side between the body and condenser!

Horn A Horn highpitch B Horn lowpitch top of page

Removing horn
Note The highpitch horn can be removed from below through the sound outlet opening! The entire front spoiler must be removed in order to remove the lowpitch horn! 1. Pull off electrical plug connection and observe installation position of the horn.

90 50 19 Removing and installing horn

1093

einordnung

2. Unscrew the M6 hexagon nut from the bracket and remove the highpitch horn through the sound outlet opening. top of page

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 hexagon nut: 10 Nm (7.5 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing horn

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91 12 15 Adjusting (calibrating) PCM navigation unit

Note GPS receiver Distance sensor Gyroscope Procedure after commissioning Procedure after changing a tyre Procedure after the power supply has been interrupted Note The PCM navigation unit must be calibrated after maintenance work or commissioning! Calibration is the prerequisite for exact route guidance! The following components of the PCM navigation unit must be calibrated or initialised: top of page

GPS receiver
Note When the power supply is disconnected (terminal 30), the builtin GPS receiver loses the socalled 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 sensor must be calibrated after commissioning of the PCM navigation unit or after changing a tyre! If a system that has already been calibrated is disconnected from the power supply (terminal 30), the calibration of the distance sensor is retained! The distance signal changes if the circumference of the tyre changes (e.g. tyre change)! This modification must be calibrated by the PCM navigation unit afterwards! The distance sensor transmits the distance travelled to the PCM navigation unit. top of page 91 12 15 Adjusting (calibrating) PCM navigation unit 1095

einordnung

Gyroscope
Note The gyroscope detects changes in the direction of travel and must be calibrated after commissioning! The gyroscope must be calibrated after commissioning only! If a system that has already been calibrated is disconnected from the power supply (terminal 30), the calibration of the gyroscope is retained! The gyroscope shows temperaturedependency. This temperaturedependency is compensated by the system if the "cold" (not calibrated) system is switched on and left to stand for approx. one hour. top of page

Procedure after commissioning

1. Switch on the PCM with a free panoramic view for approx. 20 minutes (to load GPS almanac). 2. Drive on a motorway if possible at a speed greater than 60 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 turnoffs. 4. Stop for approx. 10 seconds occasionally (calibration of the gyroscope). 5. Switch on the PCM navigation unit for approx. one hour with the vehicle horizontal. Calibration is necessary after the following maintenance work: After changing a tyre. After the power supply has been interrupted.

top of page

Procedure after changing a tyre

Drive on a motorway if possible at a speed greater than 60 km/h for a distance of approx. 50 km (calibration of the distance measurement). top of page

Procedure after the power supply has been interrupted

Procedure after the power supply has been interrupted: Switch on the PCM with a free panoramic view for approx. 20 minutes (to load GPS almanac).

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Gyroscope

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91 12 19 Removing and installing navigation unit

Note Removing navigation unit Installing navigation unit Note Special tool V 160 must be used to remove the navigation unit!

top of page

Removing navigation unit

1. Unclip the cover on the left and right of the navigation unit.

2. Insert special 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 electrical plug connections and carefully lay the electrical leads (do not pinch). 2. Clip in cover on the left and right and perform a function test.

Device code input

Note The navigation unit is protected against theft by a device code!

91 12 19 Removing and installing navigation unit

1097

einordnung Only the navigation code has to be input again if the navigation unit is exchanged.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Device code input

1098

91 13 19 Removing and installing GPS antenna

Note Removing GPS antenna Installing GPS antenna Note The GPS antenna is located under a cover in the centre of the dashboard! A lightemitting diode for the alarm system and the sun sensor are accommodated in this housing! The GPS is fastened underneath with a magnet! The 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. 3. Remove housing with GPS antenna, disconnect electrical plug connection on the bottom, and remove GPS antenna (magnet). top of page

Installing GPS antenna

1. Engage electrical plug connection and route wire carefully. 2. Install housing with GPS antenna and clip in cover.

91 13 19 Removing and installing GPS antenna

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einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing GPS antenna

1100

91 20 19 Removing and installing the car radio

Removing the car radio Installing the car radio Entering the code number top of page

Removing the car radio

1. Remove the car radio with special tool 9570/1 (see Workshop Equipment Manual Chapter 2.2). 2. Engage the special tool to the right and left in the slits provided in the car radio.

3. Carefully pull the car radio out of the holder using the special tools and disconnect the electrical plug connections. top of page

Installing the car radio

1. Remove the heating/airconditioning control. Rep. Gr. 870219; Removing and installing the heating/airconditioning control. 2. Engage the electrical plug connections on the car radio.

3. Pull the special tool out of the car radio by pressing gently on the retaining spring arrow . 4. Carefully push the car radio into place. 5. Through the opening on the heating/airconditioning control, it is possible to check the position of leads in the support frame better and to prevent leads from becoming trapped. 91 20 19 Removing and installing the car radio 1101

einordnung 6. Install the heating/airconditioning control. top of page

Entering the code number

1. If the car radio is disconnected from the power supply, it will be protected against theft the next time it is connected. 2. After being switched on with the ON key, the term CODE is displayed followed by 4 asterisks. 3. The fourfigure code number must be entered using the multifunction keys 1...0. 4. Example: code number 1530 (the code number can be found in the enclosed CODE CARD ). Enter the code number with the multifunction keys. 5. The first asterisk disappears after the first number is entered. The second asterisk disappears after the second number is entered, etc. 6. If the fourth number has been entered and all the other 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. The enclosed window stickers should be adhered to the inside of the vehicle windows! 7. If an incorrect code number has been entered, the term CODE will be displayed with the four asterisks once more. 8. If an incorrect code is entered three times, the term WAIT is displayed and the device is blocked for approx. 60 minutes. 9. Another three incorrect inputs block the device for an additional 60 minutes. 10. Important: the waiting time only counts down when the device is switched on. Note The new code number should be entered in the Motronic, test step vehicle data, using the Porsche System Tester 2!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing the car radio

1102

91 47 19 Removing and installing radio antenna

Removing radio antenna Installing radio antenna top of page

Removing radio antenna

1. Remove the cover over the heating/airconditioning system, battery and fluid tank.

2. Disconnect the antenna lead at the separation point. Just loosen the holder on the radio antenna (2 M5 x 12 screws). 3. Undo the wiper arm on the left 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 antenna and fasten it with 2 screws. 2. Install cowl panel cover and wiper arms. Engage antenna lead and fasten holder on the radio antenna. 3. Install the covers over the heating/airconditioning system, battery and fluid tank, and carry out a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

91 47 19 Removing and installing radio antenna

1103

91 57 15 Setting handsfree microphone to the telephone type

Note Setting Note There is an adjustment possibility on the handsfree microphone for adapting it to the telephone system installed in the vehicle!

The following positions must be set: Position 1: Not used Position 2: Passive operation Position 3: Active operation

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Setting
Note The setting as delivered in new cars is position 3! 1. Carefully unclip handsfree microphone from the dashboard insert and pull out. 2. Use a small screwdriver to set the position of the installed telephone system (e.g. Position 3 PCM). 3. Carefully clip the handsfree microphone into the dashboard insert again.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

91 57 15 Setting handsfree microphone to the telephone type

1104

91 57 19 Removing and installing handsfree microphone

Removing handsfree microphone Installing handsfree microphone top of page

Removing handsfree microphone

1. Disconnect the battery and cover terminal or battery. 2. Switch on the hazard warning light switch (button comes out). On the sides of the button, there are small openings that project beyond the dashboard insert.

3. Insert two small screwdrivers into the openings and pull off the button 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 switch, grip the button holder with a pair of pliers and pull out the switch. 6. Undo 5.0 x 30 Torx screw on the dashboard insert.

7. Pull out handsfree microphone on the left side and undo the 5.0 x 30 Torx screw. 8. Unclip the dashboard insert and disconnect the electrical plug connection from the handsfree microphone. 9. Pull handsfree microphone out of the dashboard insert. top of page

91 57 19 Removing and installing handsfree microphone

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einordnung

Installing handsfree microphone

1. Engage electrical plug connection of the handsfree microphone and fasten the dashboard insert onto 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 handsfree microphone, connect the battery and perform a function test.

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Installing handsfree microphone

1106

91 75 19 Removing and installing sensor for ParkAssistent

Note Removing sensor for ParkAssistent Installing sensor for ParkAssistent ParkAssistent control module Note Four sensors for the ParkAssistent are installed in the rear spoiler! The rear spoiler must be taken off in order to remove a defective sensor! When painting, make sure that not only the membrane but also the cylindrical membrane edge (2 mm) is coated with paint! Layer 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 the sensor. 4. Remove isolating ring from the sensor. top of page

Installing sensor for ParkAssistent

Note Always fit the isolating ring before installing the sensor! The electrical plug connection in the vehicle must always point to the centre of the vehicle! Plug connection with marking (white adhesive tape) on the wiring harness always connected to outer right sensor! 91 75 19 Removing and installing sensor for ParkAssistent 1107

einordnung 1. Fit isolating ring and push sensor into the sensor housing and engage. 2. Engage electrical plug connection and fit rear spoiler. top of page

ParkAssistent 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 plate (two hexagonhead screws M6 x 16).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing sensor for ParkAssistent

1108

92 15 19 Removing and installing the wiper motor

Removing wiper motor Installing wiper motor top of page

Removing wiper motor

1. Remove the covers above the battery and fluid tank. 2. Disconnect the battery and cover terminal or battery. 3. Undo the fastening nut of the link. When doing so, hold in position using an openended wrench (width across flats 21 mm). 4. Remove the link.

5. Undo the fastening screws on the wiper motor (3 M6 screws) and the lower fastening screw on the body. 6. Carefully raise the wiper link and remove the wiper motor downwards. 7. Disconnect the electrical plug connection on the wiper motor. top of page

Installing wiper motor

1. Wiper motor in parking position. 2. Fit the link.

The installation position is identified by a 0 marking (parking position) on the console (arrow) . 3. Connect the battery. 4. Switch on the wiper motor and check the wiper position. Tightening torque: Fastening screw, motor M6: 8 Nm (6 ftlb.) Tightening torque: Fastening nut, link M8: 17 Nm (12.5 ftlb.) 92 15 19 Removing and installing the wiper motor 1109

einordnung Tightening torque: Hexagonhead bolt M6: 10 Nm (7.5 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing wiper motor

1110

92 19 19 Removing and installing the wiper link

Removing wiper link Installing wiper link top of page

Removing wiper link

1. Remove the covers over the heating/airconditioning system, battery and fluid tank. 2. Disconnect the battery and cover terminal or battery. 3. Undo the wiper arm on the left and right and remove the cowl panel over the wiper 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 the front. top of page

Installing wiper link

Note Before installing the dome strut, the vehicle must be on its wheels!

1. Observe the installation sequence for the fastening screws 1 to 3 . Tightening torques: Wiper arm nut M8: 17 Nm (12.5 ftlb.) Tightening torques: Hexagonhead bolts M6: 10 Nm (7.5 ftlb.) 92 19 19 Removing and installing the wiper link 1111

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing wiper link

1112

92 27 19 Removing and installing the wiper blades

Note Note The wiper blades for the driver's and passenger's side are different! The wiper blade on the driver's side is straight! On the passenger's side it is curved A !

This arrangement applies to lefthand drive and righthand 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 installing the wiper blades for lefthand drive and righthand drive vehicles! A Clip for lefthand drive vehicles B Clip for righthand drive vehicles

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

92 27 19 Removing and installing the wiper blades

1113

92 30 19 Removing and installing rear window wiper system

Removing rear window wiper system Installing rear window wiper system top of page

Removing rear window wiper system

Note The rubber seal of the rear wiper arm remains in the rear centre panel; do not remove! The relay can be unclipped and removed with the wiper motor installed! 1. Remove cover over rearwindow wiper arm. 2. Undo the hexagon nut and pull off the rearwindow wiper arm. 3. Remove the rear panel cover in front of the rearwindow wiper motor.

4. Undo the retaining frame with rearwindow wiper motor at the rear centre panel (2 nuts, 1 screw) and pull out to the front. 5. Disconnect the electrical plug connection. top of page

Installing rear window wiper system

Note The spoiler edge on the rearwindow wiper blade must face outwards! Tightening torque: Hexagon nuts M6: 8 Nm (6 ftlb.) Tightening torque: Hexagonhead bolt M6: 8 Nm (6 ftlb.) Tightening torque: Wiper arm nut M8: 17 Nm (12.5 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

92 30 19 Removing and installing rear window wiper system

1114

92 56 19 Removing and installing pump for windscreen washer system

Removing pump for windscreen washer system Installing pump for windscreen washer system top of page

Removing pump for windscreen washer system

Note A stuck hose can be pulled off more easily if it is heated with a hotair gun! 1. Remove tank for windscreen washer system. => 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 hose off the pump. top of page

Installing pump for windscreen washer system

1. Check rubber sleeve for pump, replace if necessary. 2. Install pump and tank, fill in water and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

92 56 19 Removing and installing pump for windscreen washer system

1115

92 60 19 Removing and installing tank for windscreen washer system

Removing tank for windscreen washer system (7 litres) Removing tank for windscreen washer system (3 litres) Installing tank for windscreen washer system top of page

Removing tank for windscreen washer system (7 litres)

1. Remove left front wheel and remove the wheel housing liner. 2. Extract water from the tank if necessary and release and pull out the filler neck. 3. Disconnect the hose for 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 holder and swivel it down at the rear. 7. Disconnect electrical plug connections of pumps and fluid level indicator and remove the tank in a downward direction. top of page

Removing tank for windscreen washer system (3 litres)

1. The 3 l tank is not equipped with a headlight cleaning system.

2. The tank is fastened only by one M8 x 35 hexagonhead bolt. Tightening torque: 20 Nm (15 ftlb.)

92 60 19 Removing and installing tank for windscreen washer system

1116

einordnung top of page

Installing tank for windscreen washer system

1. First push 7 l tank under the wing at front, then engage electrical plug connections of the pumps. 2. Push tank rearward into the holder and engage the electrical plug connection for the fluid level indicator. 3. Swivel the holder back (7 l tank) and fasten the tank. Tightening torque of the hexagonhead bolts M6 x 20: 10 Nm (7.5 ftlb.) Tightening torque of the hexagonhead bolts M8 x 35: 20 Nm (15 ftlb.) 4. Engage hose for the headlight cleaning system and carefully push on the hose for the windscreen washer system. 5. Engage filler neck and fill in water. 6. Perform a function test. 7. Install wheel housing liner and mount the left front wheel. Tightening torque: 130 Nm (96 ftlb.).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing tank for windscreen washer system (3 litres)

1117

92 67 19 Removing and installing fluid level indicator

Removing fluid level indicator Installing fluid level indicator top of page

Removing fluid level indicator

1. Remove tank for windscreen washer system. => Removing 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, replace if necessary. 2. Install sensor and tank, fill in water and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

92 67 19 Removing and installing fluid level indicator

1118

92 70 19 Removing and installing cover for spray nozzle

Removing cover for spray nozzle Installing cover for spray nozzle top of page

Removing cover for spray nozzle

Note The cover for the spray nozzle can no longer be disengaged or removed. Cover and spray nozzle head are now a single spare part. 1. Actuate 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 into the spray nozzle and press down firmly until it comes into contact with the headlight lens. 2. The cover with spray nozzle head must audibly engage. 3. Perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

92 70 19 Removing and installing cover for spray nozzle

1119

92 72 19 Removing and installing spray nozzle for headlight washing system

Removing spray nozzle for headlight washing system Installing spray nozzle for headlight washing system top of page

Removing spray nozzle for headlight washing system

1. Remove and install cover for spray nozzle => Removing and installing cover for spray nozzle 2. Remove main headlight.

3. Undo the upper fastening screw (Torx T 20) on the retaining bracket. 4. Unclip lower fastening and remove retaining bracket. 5. Hold the rubber seal in the 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 sure that the rubber seal is correctly seated on the spray nozzle and in the headlight housing. 3. Clip in retaining bracket and tighten. 4. Install main headlight. 5. Insert cover with spray nozzle head into the spray nozzle and press down firmly until it comes into contact with the headlight lens. 6. The cover with spray nozzle head must audibly engage. 7. Perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

92 72 19 Removing and installing spray nozzle for headlight washing system

1120

92 78 19 Removing and installing pump for headlight washing system

Removing pump for headlight washing system Installing pump for headlight washing system top of page

Removing pump for headlight washing system

Note A stuck hose can be pulled off more easily if it is heated with a hotair gun! 1. Remove tank for windscreen washer system. => 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. Remove spacer between the pumps and lift pump upwards out of the rubber sleeve. 4. Pull hose off the pump. top of page

Installing pump for headlight washing system

1. Check rubber sleeve for pump, replace if necessary. 2. Install pump and tank, fill in water and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

92 78 19 Removing and installing pump for headlight washing system

1121

94 05 19 Removing and installing main light switch

Removing main light switch Installing main light switch top of page

Removing main light switch

1. Disconnect the battery and cover terminal or battery.

2. Remove button of the light switch. Pull out the button as far as it will go and press in the locking element on the lower side 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. Disconnect the electrical plug connections. 5. Undo M16 x 1 hexagon nut of the light switch. 6. Pull the lighting unit switch out of the side vent to the front by approx. 5 mm.

7. Remove light switch from the side vent by turning it slightly in clockwise direction. top of page

94 05 19 Removing and installing main light switch

1122

einordnung

Installing main light switch

1. Engage light switch by turning it slightly in counterclockwise 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, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing main light switch

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94 15 01 Troubleshooting on the Xenon headlight

Caution WARNING Danger of injury from high voltage! The light should always be switched off when the components (control module, gas discharge lamp, drive motor) are removed and installed! The gas discharge lamp (D2S lamp) should only be operated when installed in the reflector and in the installed headlight! A removed headlight does not 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 can be checked with the headlight removed on the plug connection, to Pin 5 = 56a, Pin 11 = 56b and Pin 12 = 31, according to the wiring diagram in the wing! The gas discharge lamp should only be operated when installed in the reflector and in the installed headlight!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 15 01 Troubleshooting on the Xenon headlight

1124

94 15 05 Main headlights basic adjustment in the body

Note Adjustment instructions Adjustment procedure Note The main headlights have been fitted into the body at the factory! A new adjustment may only be made in the case of accident repairs or replacement of the main headlights!

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Adjustment instructions

Note The headlight cover plate should lie approximately 2 mm below the body edge! The transition from the headlight housing to the body is in the same plane (level).

94 15 05 Main headlights basic adjustment in the body

1125

einordnung Factory fitting of the adjusting component fastening nuts

Fitting of the fastening nuts in the case of accident repairs or replacement of the main headlights

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Adjustment 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 adjustment, tighten the fastening nuts. Tightening torque: 8 2 Nm ( 6 1.5 ftlb.)

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Adjustment instructions

1126

94 15 15 Left / right traffic conversion for Xenon headlights

Caution Converting Xenon headlights Installation WARNING Warning signs (yellow triangle with black highvoltage arrow) indicate high voltage (risk of fatal injury)! The light should always be switched off when the components (control module, gas discharge lamp, drive motor) are removed and installed. A removed headlight does not have a high voltage. The gas discharge lamp (D2S lamp) should only be operated when installed in the reflector and in the installed headlight. Note The masking film for left/righthand traffic should not be removed from Xenon headlights! In the headlight there is a changeover lever for driving in countries with left or righthand traffic! The changeover lever is located on the left and right of the housing beside the gas discharge lamp!

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Converting Xenon headlights

1. Switch off light. Remove main headlight. 2. Unscrew fastening screws (2 ea.) and open rear closure cap.

3. Put changeover lever into position T (tourist setting) using an 8 mm socket wrench insert. top of page

Installation
1. Close cap and secure with fastening screws. 2. Install main headlight and perform a function test. 3. Repeat conversion for other headlight.

94 15 15 Left / right traffic conversion for Xenon headlights

1127

einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installation

1128

94 15 19 Removing and installing the main headlights

Note

Note

Switchedon headlights must not be covered by a front apron 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, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 15 19 Removing and installing the main headlights

1129

94 23 19 Removing and installing gas discharge lamp (Xenon headlights)

Caution Removing gas discharge lamp (Xenon headlights) Installing gas discharge lamp (Xenon headlights) WARNING Danger of injury from high voltage! The light should always be switched off when the components (control module, gas discharge lamp, drive motor) are removed and installed! The gas discharge lamp (D2S lamp) should only be operated when installed in the reflector and in the installed headlight! A removed headlight does not have a high voltage! Gloves must be worn when changing the lamp! Do not touch the glass bulb!

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Removing gas discharge lamp (Xenon headlights)

1. Switch off light. Remove main headlight. 2. Unscrew fastening screws (2 ea.) and open rear closure cap. 3. Undo electrical plug connection on the gas discharge lamp (bayonet lock). 4. Turn lamp fastener counterclockwise (bayonet lock) and remove with the gas discharge lamp. top of page

Installing gas discharge lamp (Xenon headlights)

1. Install new gas discharge lamp. Position lamp fastener (lower arrow) and turn to the right. 2. Engage electrical plug connection. 3. Close cap and secure with fastening screws. 4. Install main headlight and perform a function test.

94 23 19 Removing and installing gas discharge lamp (Xenon headlights)

1130

einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing gas discharge lamp (Xenon headlights)

1131

94 27 19 Removing and installing bulb for parking light

Removing bulb for parking light Installing bulb for parking light top of page

Removing bulb for parking light

1. Switch off light. Remove main headlight.

2. Open side cover and turn the parking light bulb 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 bulb and engage parking light bulb socket in the reflector. 2. Close cover and install main headlight. 3. Perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 27 19 Removing and installing bulb for parking light

1132

94 29 19 Removing and installing bulb for number plate light

Removing bulb for number plate light Installing bulb for number plate light top of page

Removing bulb for number plate light

1. Loosen both fastening screws and remove the number plate light. 2. Push 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 rubber cover (protects against water leaking in) carefully over the number plate light and fasten. 3. Perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 29 19 Removing and installing bulb for number plate light

1133

94 33 19 Removing and installing bulb for tail light

Removing bulb for tail light Installing bulb for tail light top of page

Removing bulb for tail light

1. Open engine compartment lid.

2. Unscrew fastening screws and pull out the tail light towards the rear. A Rear fog light B Tail light C Tail light/brake light D Reversing light E Direction indicator light 3. Turn bulb socket counterclockwise 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 bulb and ensure that it is correctly seated (bayonet lock). 2. Rotate bulb socket clockwise and engage. 3. Install the tail light, making sure the retaining lugs are seated properly. 4. Perform a function test of all bulbs.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 33 19 Removing and installing bulb for tail light

1134

94 47 19 Removing and installing the hazard warning light switch

Removing hazard warning light switch Installing hazard warning light switch top of page

Removing hazard warning light switch

1. Switch on the hazard warning light switch (button comes out). On the sides of the button, there are small openings that project beyond the dashboard insert.

2. Insert two small screwdrivers into the openings and pull off 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 the switch, grip the button holder with a pair of pliers and pull out the switch toward the front. top of page

Installing hazard warning light switch

1. Press button A onto the hazard warning light switch B until the button is heard to engage. 2. Perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 47 19 Removing and installing the hazard warning light switch

1135

94 53 19 Removing and installing bulb for side direction indicator light

Removing bulb for side direction indicator light Installing bulb for side direction indicator light top of page

Removing bulb for side direction indicator light

1. Insert a screwdriver in the upper slot between the wheel housing liner and the direction indicator light housing. 2. Unclip the retaining spring of the direction indicator light housing by pressing with the screwdriver. 3. Release and pull off electrical plug connection. 4. Turn bulb socket counterclockwise and remove (bayonet lock). 5. Remove defective bulb. top of page

Installing bulb for side direction indicator light

1. Insert new bulb in the bulb socket and install (bayonet lock). 2. Engage electrical plug connection and install direction indicator light. 3. Insert tabs of direction indicator light arrow A forwards into the wing.

4. Engage retaining spring arrow B in the wing. 5. Perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 53 19 Removing and installing bulb for side direction indicator light

1136

94 57 19 Removing and installing control module for gas discharge lamp

Caution Removing control module for gas discharge lamp Installing control module for gas discharge lamp WARNING Danger of injury from high voltage! The light should always be switched off when the components (control module, gas discharge lamp, drive motor) are removed and installed! The gas discharge lamp (D2S lamp) 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. Switch off light.

2. Remove main headlight. 3. Detach the holder from the control module and remove. 4. Release and pull off electrical plug connection from the control module.

5. Unscrew fastening screws (2 ea.) and open rear closure cap. 6. Undo electrical plug connection on the gas discharge lamp (bayonet lock). 7. 94 57 19 Removing and installing control module for gas discharge lamp 1137

einordnung Unclip the wiring arrangement from the closure cap and remove the control module with the closure cap wire. top of page

Installing control module for gas discharge lamp

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 headlight and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing control module for gas discharge lamp

1138

94 66 19 Removing and installing bulb for auxiliary headlight (high beam headlight)
Removing bulb for auxiliary headlight Installing bulb for auxiliary headlight top of page

Removing bulb for auxiliary headlight

Note The bulb for auxiliary headlights (high beam headlight/headlight flasher) is located beneath the gas discharge lamp for dipped beam/high beam headlight! 1. Switch off light. Remove main headlight. 2. Unscrew fastening screws (2 ea.) and open rear closure cap. Unscrew bulb for the auxiliary headlight (bayonet lock). 3. Release and disconnect electrical connection of the defective bulb. top of page

Installing bulb for auxiliary headlight

1. Engage electrical plug connection. Install new bulb and ensure that it is correctly seated. 2. Close cap and secure with fastening screws. 3. Install main headlight and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 66 19 Removing and installing bulb for auxiliary headlight (high beam headlight)

1139

94 67 19 Removing and installing bulb for fog light

Removing bulb for fog light Installing bulb for fog light top of page

Removing bulb for fog light

1. Switch off light. Remove main headlight. 2. Rotate the round cover in the headlight housing counterclockwise and remove.

3. Disconnect electrical 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 ensure that it is correctly seated. 2. Attach retaining bracket and engage electrical plug connection. 3. Close cover and install main headlight. 4. Perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 67 19 Removing and installing bulb for fog light

1140

94 70 19 Removing and installing bulb for additional brake light

Removing bulb for additional brake light Installing bulb for additional brake light top of page

Removing bulb for additional brake light

1. Carefully lever out the righthand corner segment of the light lens with the screwdriver blade. 2. Pull corner segment out of the lock.

3. Turn lock of the additional brake light approx. 90 counterclockwise 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 additional brake light

1. Insert new bulb in the bulb holder. 2. Engage fastening tabs and connect electrical plug connection. 3. Insert additional brake light and turn lock approx. 90 clockwise. 4. Push corner segment into the lock and clip it in. 5. Perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 70 19 Removing and installing bulb for additional brake light

1141

94 78 19 Removing and installing front angle sensor for headlight beam adjustment
Removing front angle sensor for headlight beam adjustment Installing front angle sensor for headlight beam adjustment top of page

Removing front angle sensor for headlight beam adjustment

1. Remove front underside panel. 2. Hold intermediate link on rotary lever with second openended wrench and release.

3. Push back the rubber cover over the electrical 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 bracket and remove it. top of page

Installing front angle sensor for headlight beam adjustment

Note Once the angle sensor has been installed, the control module must be recalibrated with the Porsche System Tester 2! After this, the main headlights must be readjusted with a commercially available 5 mm ballhead screwdriver (free blade length 150 mm)!

94 78 19 Removing and installing front angle sensor for headlight beam adjustment

1142

einordnung 1. Fasten angle sensor on the retaining bracket and install. 2. Engage electrical plug connection and pull rubber cover carefully over the plug 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

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing front angle sensor for headlight beam adjustment

1143

94 79 19 Removing and installing rear angle sensor for headlight beam adjustment
Removing rear angle sensor for headlight beam adjustment Installing rear angle sensor for headlight beam adjustment top of page

Removing rear angle sensor for headlight beam adjustment

1. Hold intermediate link on rotary lever with second openended wrench and release. 2. Push back the rubber cover over the electrical plug connection and remove electrical plug connection from the angle sensor.

3. Detach retaining bracket for angle sensor, combination wire and brake line on the body. 4. Detach the 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 recalibrated with the Porsche System Tester 2! After this, the main headlights must be readjusted with a commercially available 5 mm ballhead screwdriver (free blade length 150 mm)! 1. Fasten angle sensor on the retaining bracket and install. 2. Engage electrical plug connection and pull rubber cover carefully over the plug connection (protects against water leaking in). 3. Secure the linkage to the rotary lever. Tightening torque: 7 Nm (5 ftlb.) Adjust the main headlights: 0 Entire vehicle General

94 79 19 Removing and installing rear angle sensor for headlight beam adjustment

1144

einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing rear angle sensor for headlight beam adjustment

1145

94 94 19 Removing and installing drive motor for headlight beam adjustment

Caution Removing drive motor for headlight beam adjustment Installing drive motor for headlight beam adjustment WARNING Danger of injury from high voltage! The light should always be switched off when the components (control module, gas discharge lamp, drive motor) are removed and installed! The gas discharge lamp (D2S lamp) 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 drive motor for headlight 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 fastening screws (2 screws). 4. Swivel drive motor to the side and remove towards the rear. top of page

Installing drive motor for headlight beam adjustment

1. Install new drive motor. Install the ball head into the ball socket from the side and secure the drive motor. 2. Engage the electrical plug connection on the drive motor. 3. Close cap and secure with fastening screws. 4. Install main headlight and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

94 94 19 Removing and installing drive motor for headlight beam adjustment

1146

94 98 19 Removing and installing control module for headlight beam adjustment

Note Removing control module for headlight beam adjustment Installing control module for headlight beam adjustment Note The control module is fastened on the right side of the dashboard beneath the passenger airbag unit!

top of page

Removing control module for headlight beam adjustment

1. Remove footwell bulkhead and right air guide. 2. Undo control module from below (2 sheetmetal screws).

3. Unlock the electrical 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 System Tester 2! After this, the main headlights must be readjusted with a commercially available 5 mm ballhead screwdriver (free blade length 150 mm)! 1. Lock the electrical plug connection and fasten the control module to the bracket. 2. Install the right air guide and footwell bulkhead. Adjust the main headlights: 0 Entire vehicle General

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841 94 98 19 Removing and installing control module for headlight beam adjustment 1147

96 16 19 Removing and installing bulb for door warning light

Removing bulb for door warning light Installing bulb for door warning light top of page

Removing bulb for door warning light

1. Press out door warning light 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 and install. 2. Install door warning light in the door trim panel and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

96 16 19 Removing and installing bulb for door warning light

1148

96 22 19 Removing and installing bulb for interior light

Removing bulb for interior light Installing bulb for interior light top of page

Removing bulb for interior light

1. Pull the interior light out of the trim panel carefully from the front. 2. Remove bulb for reading light. Disengage the bulb socket (bayonet lock) and remove defective bulb.

3. Remove interior light. Carefully unclip the light lens on the switch side arrow and 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. Insert the new bulb for the interior light into the holes of the contact springs and clip in the light lens. 3. Install interior light. First insert into the trim panel at the rear, then press upwards at the front and engage. 4. Carry out a function test for the reading light and interior light.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

96 22 19 Removing and installing bulb for interior light

1149

96 41 19 Removing and installing bulb for luggage compartment light

Removing bulb for luggage compartment light Installing bulb for luggage compartment light top of page

Removing bulb for luggage compartment light

1. Press luggage compartment light 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 of the contact springs. 2. Install luggage compartment light in the trim panel and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

96 41 19 Removing and installing bulb for luggage compartment light

1150

96 43 19 Removing and installing bulb for engine compartment light

Removing bulb for engine compartment light Installing bulb for engine compartment light top of page

Removing bulb for engine compartment light

1. Press engine compartment light 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 the contact springs. 2. Install engine compartment light into the fan cover and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

96 43 19 Removing and installing bulb for engine compartment light

1151

96 62 01 Radio remote control in handheld transmitter does not function

Empty battery in handheld transmitter Radio transmitter outside lockin range Atmospheric interference or interfering transmitters Energysaving mode active Fault in handheld transmitter or vehicle The radio remote control function is unavailable under the following five circumstances: top of page

Empty battery in handheld transmitter

Battery replacement restores the full functionality without additional measures. The same applies in the case of an empty vehicle battery.

top of page

Radio transmitter outside lockin range

Note If the transmitter is operated more than 256 times without reaching the associated receiver e.g. vehicle outside range or vehicle battery disconnected the vehicle will not recognise the radio transmitter the next time it is operated! If the number of operations is less than 1024, it is possible to perform resynchronisation! Resynchronisation is carried out according to the following procedure: Switch on ignition with key and valid transponder. Switch off ignition. Remove ignition key from steering lock. Operate transmitter within 6 seconds after the key has been removed. The lockin range has now been reset to zero (as is the case with every recognised transmitter operation). top of page

Atmospheric interference or interfering transmitters

The possibility of temporary interference by interference sources, and thus lack of function, cannot be ruled out due to the many small users operating on the radio frequencies permissible for the automotive application. The 996 model can be unlocked with the vehicle key via the door lock in the event of interference. Unlike with the 993, this does not affect the immobilizer. Deactivation of the immobilizer is performed via the transponder in the key head as soon as the key is turned in the steering lock. 96 62 01 Radio remote control in handheld transmitter does not function 1152

einordnung top of page

Energysaving mode active

In order to keep "breakdowns" resulting from an empty battery to a minimum, the radio receiver, which draws a high closedcircuit current, is switched off in the alarm system control module after a certain time in addition to switchoff of the other loads. The radio receiver is switched off if the ignition is not switched on again within five days (120 h OFF time). The radio receiver is switched off independently of the locking condition of the vehicle. A locked vehicle can be unlocked with the vehicle key. (This does not reactivate the radio receiver). In order to avoid triggering the alarm, the vehicle key with valid transponder must be turned in the steering lock within the vehicleentering delay of 10 seconds (due to the "passive arming" function automatic arming of the alarm system 30 seconds after the vehicle is left with the ignition key removed; the central locking system is 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 by switching on the ignition again. The switchoff time is reset if the ignition is switched on within five days, i.e. the system does not enter energysaving mode. If a valid radio command is recognised within the idle period (terminal 15 off), the switchoff time is not reset.

top of page

Fault in handheld transmitter or vehicle

If the LED on the handheld transmitter stays dark when the transmitter is operated, this is an indication of either an empty battery or a faulty handheld transmitter. Radio transmission is OK if the LED on the transmitter flashes when the transmitter is operated and the alarm readiness lamp on the dashboard flashes rapidly. Note If the alarm readiness light stays dark and chapters 1 to 4 can be excluded, the problem is a system fault of the vehicle!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Atmospheric interference or interfering transmitters

1153

96 62 37 Disassembling and assembling handheld transmitter

Note Removing key from the bottom part Installing key in the bottom part Note The top part of the handheld transmitter is carefully lifted off with the fingernail or a small screwdriver!

top of page

Removing key from the bottom part

1. In order to remove the key from the bottom part, the compression spring in the sliding latch is compressed and held with a small 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 replacement key into the bottom part. 2. Install sliding latch and compression spring. Compress and hold compression spring using a small screwdriver. 3. Insert the cap from above and relieve the compression spring. 4. Press the top and bottom parts of the handheld transmitter together firmly.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

96 62 37 Disassembling and assembling handheld transmitter

1154

96 62 55 Teaching handheld transmitter

General Work preparation Procedure top of page

General
Up to four handheld transmitters can be adapted to the control module. The handheld transmitter can be used to activate the central locking and the convertible top (for 996 Cabrio, countryspecific version). Another function is the immobilizer by means of the integrated transponder coil. top of page

Work preparation
Note If the key is stolen or the handheld transmitter is faulty, all keys still in the customer's possession will be required! The following information is required to teach the handheld transmitter: Key learning code from IPAS 24digit Code No. (see barcode label on key grip) Note During maintenance work, please bear in mind that the transmission frequency of the handheld transmitter is different according to the country of use! The corresponding reception frequency is printed on the alarm system control module! This reception frequency is either: 433 Mhz with Mnumber M534 or 315 Mhz with Mnumber M535

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96 62 55 Teaching handheld transmitter

1155

einordnung

Procedure
1. Connect the vehicle keys and the new handheld transmitter and insert in the ignition. 2. Connect PST 2 and switch on ignition. 3. Select Alarm system in the menu and press the double arrow key >> . 4. Select Learning function in the menu and press the double arrow key >> 5. Select menu item Transponder key and press the double arrow key >> . The following message appears on the screen: "Input key learning code". 6. With the arrow keys, input the key learning code and press the double arrow key >> . The following message appears on the screen: "Please confirm input". 7. Check the input and press the F7 key to confirm the input. 8. Distinguish between loss and fault and additional handheld transmitter for the transponder. a) Teaching an additional handheld transmitter: With the arrow key, select a free position (1, 2, 3 or 4) and press the F8 key. Now the transponder code is saved in the selected position. Note the position of the new transponder code. b) Teaching in the case of a lost or faulty handheld transmitter: Note Risk of theft due to the lost handheld transmitter! It is essential to identify and delete the transponder code of the lost handheld transmitter as described in step 8 b)! It is essential to identify and delete the radio code of the lost handheld transmitter as described in step 12 b)! In this case, it is first necessary to identify and delete the stored transponder code of the lost handheld transmitter. The remaining vehicle keys are required for this purpose: One after the other, insert the keys into the ignition lock, switch the ignition on and establish communication with the control module. Current transponder shows the transponder code of the vehicle key that is presently inserted in the ignition lock Compare this transponder code with the transponder codes at positions 1 to 4. This comparison allows the position of the lost handheld transmitter (transponder code) to be identified, as one transponder code is ultimately left over at positions 1 to 4. Insert the vehicle key equipped with the new handheld transmitter into the ignition lock and switch on the ignition. Establish communication between the PST2 and the control module. Select the identified position using the arrow keys and delete the transponder code with the F3 key. Then press the F8 key. 9. Procedure 1156

einordnung Press the double arrow key << , select the menu item Remote control and press the double arrow key >> . "Input key learning code" appears on the screen 10. With the arrow keys, input the key learning code and press the double arrow key >> . The following message appears on the screen: "Please confirm input". 11. Check the input and press the F7 key to confirm the input. 12. Distinguish between loss and fault and additional handheld transmitter for the radio code. a) Teaching an additional handheld transmitter: Select the same position (1 to 4) as for the transponder key and press the [F8] key. b) Teaching in the case of a lost or faulty handheld transmitter: 13. In this case, it is first necessary to identify and delete the stored "radio code" of the lost handheld transmitter. The remaining handheld transmitters are required for this purpose. Press the locking button on the handheld transmitter and then insert the vehicle key into the ignition lock, switch on the ignition and reestablish communication with 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 comparison allows the position of the lost handheld transmitter (radio code) to be identified, as one "radio code" is ultimately left over at positions 1 to 4. Insert the vehicle key equipped with the new handheld transmitter into the ignition lock and switch on the ignition. Establish communication with the control module. Select the identified position using the arrow keys and delete the radio code with the F3 key. Then press the F8 key. 14. Carefully input the 24 digit code number with the arrow keys and press the double arrow key >> . The following message appears on the screen: "Please confirm input". 15. Check the input and press the F7 key. Now the handheld transmitter is taught. 16. Go back to the menu item Learning function, remove the key and switch on the ignition again. Once the key has been removed again, the handheld transmitter is ready for use. 17. Check handheld transmitter for operation.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Procedure

1157

96 72 19 Removing and installing signal converter/immobilizer

Removing signal converter/immobilizer Installing signal converter/immobilizer top of page

Removing signal converter/immobilizer

Note The signal converter on the ignition steering lock housing can be removed through the opening in the 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) crosshead screwdriver (1/4 turn counterclockwise).

4. Pull the signal converter housing out of the holder to the rear. 5. Unlock the electrical plug connection from above and disconnect. 6. Remove signal converter housing out of the side vent opening. top of page

96 72 19 Removing and installing signal converter/immobilizer

1158

einordnung

Installing signal converter/immobilizer

1. Close locking button of the signal 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, 996651, 996840, 996841

Installing signal converter/immobilizer

1159

96 85 19 Removing and installing passenger compartment monitoring sensor

Removing and installing passenger compartment monitoring sensor Removing and installing passenger compartment monitoring sensor top of page

Removing and installing passenger compartment monitoring sensor

1. Using a small screwdriver, carefully unclip both cover lenses at the openings provided.

2. Undo fastening screws M 5 with a crosshead screwdriver A . 3. Unclip sensor 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 from the sensor holder. top of page

Removing and installing passenger compartment monitoring sensor

Note Do not press on or touch the transmission/reception diodes with your fingers! The cover lenses must not be soiled or smudged with grease! 1. Engage the electrical plug connections and carefully lay the electrical cables (do not pinch). 2. Clip in cover lenses again.

96 85 19 Removing and installing passenger compartment monitoring sensor

1160

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing and installing passenger compartment monitoringsensor

1161

97 09 41 Repair of main wiring harness

Note Removing main wiring harness Installing main wiring harness Note The combination wires for ABS and BVA are integrated in the wiring harness. In the event of damage, the integrated wires can be disconnected and replaced by repair wires. The disconnection points are located at the front left and front right above the radiator 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 intact.

Disconnection point, front left: Join wires between the arrows with crimp connectors.

Disconnection point, front right: Join wires between the arrows with crimp connectors.

top of page

Removing main wiring harness

1. Take off cover of battery and radiator tank. 2. Disconnect the battery and cover terminal or battery. 3. 97 09 41 Repair of main wiring harness 1162

einordnung Remove front wheel housing liner. Undo cable ties in the area of the wheel housing, and remove combination wire. 4. Carefully remove insulating tape from the combination wire in the area of the disconnection point and cut the old combination wire before the exit to the wheel housing (do not damage any other wires). top of page

Installing main wiring harness

1. Install repair wire in the wheel housing. Join wires as specified in the table using a crimp connector and crimping tool (see Workshop Equipment Manual No. 155 1). 2. Colour coding of left and right hand 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. Combination wire, colour/length (mm): br/bk 20 br/gn 40 br/wt 60 br/bu 80 br 100 Frontend wire, colour/length (mm): br/bk 100 br/gn 80 br/wt 60 br/bu 40 br 20 4. Exercise caution when stripping insulation from wiring. Other wires must not be damaged. 5. Push on the supplied heatshrinking tubes. 6. Push the large heatshrinking tube over all wires. 7. Strip 10 mm of insulation off the wires. 8. Join wires using crimp connector. 9. Shrink shrinkfit hoses with a hotair gun. 10. It is essential that all wires are watertight.

Removing main wiring harness

1163

einordnung 11. Wrap commercially available PVC tape all around the area of the connection points.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing main wiring harness

1164

97 25 41 Repair of rear wiring harness

Note Removing rear wiring harness Installing rear wiring harness Note The combination wires for ABS and BVA are integrated in the wiring harness. In the event of damage, the integrated wires can be removed and replaced by repair wires. The disconnection point is the plug connection X 2/4 passenger compartment/rear end (white) or connection points. The plug connection is situated behind the driver s seat on the left beneath the belt reel. 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 intact.

Plug connection X 2/4, (Pfeil) passenger compartment/rear end: Install preassembled contacts or join wires at connection points.

top of page

Removing rear wiring harness

1. Disconnect the battery and cover terminal or battery. 2. Undo combination wire in the area of the rear wheel housing. 3. Remove trim of seat well and cover of rear side member. 4. Undo rubber grommet, unclip combination wire on inside and open wiring duct. 5. Uncover combination wire in the interior as far as plug connection X 2/4 and disconnect plug connection (do not damage any other wires). top of page

97 25 41 Repair of rear wiring harness

1165

einordnung

Installing rear wiring harness

1. Install repair wire in wheel housing and route in the wiring duct as far as plug connection X 2/4. 2. Join wires at the connection points using a crimp connector and crimping tool (see Workshop Equipment Manual No. 155 1). Install preassembled contacts in plug connection X 2/4. 3. Colour coding of left and right hand 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

4. Unlocking tool to unlock the old contacts in the plug connection (see Workshop Equipment Manual, No. 155). 5. Unlock the old contacts of the combination wire with the unlocking tool, and remove. Install new contacts of the repair wire in the same location.

6. Plug connection X 2/4 (white). 7. Combination wire, rear left: Combination wire ABS and BVA in plug connection x 2/4 (white) br/wt in pin 16 (ABS) br/wt in pin 16 (ABS) br/gr in pin 20 (BVA) Installing rear wiring harness 1166

einordnung 8. Combination wire, rear right: br/wt in pin 18 (ABS) br/bu in pin 19 (ABS) 9. The ground leads of the combination wires (brown) are the same on both right and left. Connection point No. 48 as shown in circuit diagram. 10. Strip 10 mm of insulation off the wires. 11. Push on heatshrinking tube. 12. Using a crimp connector, join brown wire of combination wire to brown wire of rearend wiring harness 13. Shrink heatshrinking tube with a hotair gun so that wires are watertight. 14. BVA wire of combination wire (brown/green) at ?connection point No. 47 as shown in circuit diagram. 15. Strip 10 mm of wire. 16. Push on heatshrinking tube. 17. Using a crimp connector, join brown/green wire of combination wire to brown/green wire of rearend wiring harness. 18. Shrink heatshrinking tube with a hotair gun so that wires are watertight. 19. The BVA wires of the combination wires (brown/black) are the same on both right and left. Connection point No. 46 as shown in circuit diagram. 20. Strip 10 mm of wire. 21. Push on heatshrinking tube. 22. Using a crimp connector, join brown/black wire of combination wire to brown/black wire of rearend wiring harness. 23. Shrink heatshrinking tube with a hotair gun so that wires are watertight. 24. Wind commercially available PVC tape around wires.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing rear wiring harness

1167

10 01 19 Removing and installing engine

Tools for removal Removing engine top of page

Tools for removal

Item Designation of the special tool 1 Engine retainer plate 9111/3 2 Adapter 9111/1 3 Spacer 9111/5 4 Support plate with wooden supports 9111/4 Additional support 9111/6

Explanation

To compensate for the engine retainer plate in the necessary horizontal position Separate the wooden supports and only fasten one half in each case on the support plate Required only for removal or installation with Tiptronic transmission. The additional support prevents the enginetransmission unit from tilting off the engine plate

10 01 19 Removing and installing engine

1168

einordnung

Item Designation of the special Explanation tool A Removal tool Commercially available (refer to Workshop Equipment Manual, Chapter 2.4, No. 21)

top of page

Removing engine
1. Read out the fault memory with the Porsche System Tester 2 and print it out if necessary. 2. Open engine compartment lid. 3. Install protective supports. 4. Disconnect the battery and cover terminal or battery. CAUTION 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 plate of the lifting platform into the highest position! Note Make sure the outer screw connections for the diagonal braces are accessible! WARNING Danger of injury if the clutch pressure line is undone or disconnected without pressure reduction beforehand! Reduce pressure in the clutch system! Actuate clutch pedal at least 25 times for this purpose! Tools for removal 1169

einordnung

5. Pull off the right and left pressure hoses; to do so, lever off the retaining clips.

6. Undo hexagonhead bolt M6 x 34.

7. Remove the complete air cleaner assembly.

8. In order to remove the pressure pipe, loosen the hexagonhead bolts, the hose clamp and the plug. 9. Disconnect vacuum hose from the switchover valve and remove the switchover valve from the holder. After removing the presure hose, refit the retaining clip.

Removing engine

1170

einordnung

10. Detach the holder over the airconditioning compressor.

11. Undo the fuel supply line on the fuel cooler. It is very important to counter when performing this step. Union nut a/f 17, counter with a/f 14. 12. Unscrew the hexagonhead bolts M8 x 12 on the belt pulley by approx. half a revolution. 13. Relieve drive belt and remove from the belt pulley of the hydraulic pump. 14. Remove belt pulley. 15. Disconnect the hydraulic lines with plugin coupling on the expansion tank. Note 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!

Insert tool between line and the red unlocking ring and unlock by pulling black line to the right and simultaneously pressing the tool against the red unlocking ring. 16. Unscrew the 2 fastening screws (M8 x 25 with hexagon socket head bolts) on the tank. Removing engine 1171

einordnung 17. Unscrew 3 screws (M8) and 1 screw (M6) between the hydraulic pump and the bracket. 18. Pull the expansion tank with hydraulic pump out of the bracket and lay to the side.

19. Remove throttle body. 20. Remove the compressor. Note 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 bayonet lock) on the right side in the engine compartment.

22. To do this, turn round plugs counterclockwise and pull them off.

23. Disconnect oxygen sensor plug connections using a screwdriver.

Removing engine

1172

einordnung

24. Disconnect oxygen sensor plug connections on the rear closing panel.

25. Unscrew the stabilizer. 26. Remove the front cross member and both diagonal braces.

27. Remove the rear cross member. To do this, only loosen the two upper hexagonhead bolts (M12 x 83) (there are slots in the cross member). Note Remove hexagonhead bolts in order to avoid damage to the reference mark sender cable or the oil tank when the enginetransmission unit is subsequently lowered. 28. Unscrew and remove the halfshafts. Note Always use the protective support! 29. Pull off plug for reversing light on the transmission.

Removing engine

1173

einordnung

30. Detach and remove the transmission support.

31. Detach cardan shaft on transmission flange. Note A second person should counter the cardan shaft when it is being removed! 32. Pull cardan shaft out of the frontaxle final drive and set it aside. 33. Disengage shift cables with 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, universal joint, hexagon wrench insert a/f 15. Undo the lower fastening screw. Remove starter.

35. Loosen both intake pipes on the exhaust turbocharger. Also disconnect the plug for the boost pressure check on the left hand side. Remove intake pipes.

Removing engine

1174

einordnung

36. Undo ground strap between engine and right side member (in area above cylinder 6).

37. Disconnect the clutch pressure line. WARNING Danger of injury if the clutch pressure line is undone or disconnected without pressure reduction beforehand! Reduce pressure in the clutch system! Actuate 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 B ! Disengage lead out of the holder. Plug lines. 38. Screw closure cap off coolant expansion tank.

39. Undo coolant drain plug on right and left and drain the coolant. 40. Equip drain plugs with new sealing rings. Tightening torque: 10 + 5 Nm (7.5 + 3.5 ftlb.) Removing engine 1175

einordnung

41. Remove coolant hoses. 42. Place workshop jack and preassembled engine retainer plate underneath with slight load.

Spacer 9111/5 fitted

Engage support lever in horizontal position. 43. Undo transmission support. 44. Separate engine carrier from the engine mounts (wrench size 18). 45. Carefully and in steps, lower the enginetransmission unit by approx. 10 cm. 46. The following parts must be undone or removed from this position: Disconnect plug connection of tank vent. Press unlocking buttons and simultaneously pull off the line. 47. Disconnect vacuum line for the brake booster

Removing engine

1176

einordnung

Remove snap ring of vacuum line for the brake booster.

Push the inner sleeve (arrow 1) against the outer sleeve (arrow 2) and pull off both sleeves together in the direction of the arrow.

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 air distributor is detached from the engine and remains in the engine compartment.

49. Undo the hose clamp and remove from the intake air distributor.

Removing engine

1177

einordnung

50. Undo the hexagonhead bolt and lift the complete intake air distributor up and out of the support pins.

51. Suspend intake air distributor in the engine compartment. Note While lowering, have a second person observe the enginetransmission 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 workshop, the rear cross member should be refitted under all circumstances to maintain the structural strength!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Removing engine

1178

10 01 19 Removing and installing engine

Installing engine Tightening torques: Removing and installing engine top of page

Installing engine
Note The enginetransmission unit is installed in the reverse order. The following points must be given special attention! 1. Lift the enginetransmission unit carefully and in steps. Note Have a second person observe the enginetransmission 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 must be carried out before the final installation position is reached: Fasten lower coolant hose to expansion tank.

Position the intake air distributor on the support pins and simultaneously fit the line of the switchover valves. Fasten the hexagonhead bolt.

3. Fasten vent line on the intake air distributor.

10 01 19 Removing and installing engine

1179

einordnung

Fasten fuel filter, fuel supply line (1) and fuel return (2). Tighten the fuel supply line to 30 to 35 Nm (22 to 26 ftlb.) and the fuel return line to 25 Nm (19 ftlb.).

After the screw union of the fuel return line has been retightened, there must be a minimum 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 and fit plastic snap ring. 4. Fit engine wiring harness. The round plugs are colourcoded on the inside: upper round plug black lower round plug grey

Line up marking of the round connector with marking on the housing.

Installing engine

1180

einordnung

Turn round connector clockwise by approx. 90 (bayonet lock).

5. Insert spacer sleeve. 6. Fit airconditioning compressor. 7. Fit drive belt. Note Observe sequence when fitting the belt! 8. Fit coolant hoses with new Orings and plenty of water. 9. Attach the safety brackets onto the coolant supports before 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 cooler and throttle body with new Orings and wet with plenty of water. 12. Attach the safety brackets (locking springs) onto the pressure pipe before engaging the pressure hoses. Note The pressure hoses must audibly engage! 13. Check correct seating by pulling gently.

Installing engine

1181

einordnung

14. Fit crash support again. Coat the fastening screws with Loctite 574 and fasten. Tightening torque 23 Nm (17 ftlb.). 15. Bleed steering system. 16. Bleed cooling system with the System Tester 2, under menu item "Special functions" top of page

Tightening torques: Removing and installing engine

Location Engine mount to engine carrier Transmission support to body Drive shaft to transmission Wheel to wheel hub Rearaxle member to carrier side section Cross member at front to carrier side section Diagonal brace to body Diagonal brace to cross member Diagonal brace to carrier side section (collar nut) Stabilizer to carrier side section Stabilizer to stabilizer mount Ground strap to body Fuel return line Fuel supply line Coolant drain plug Cardan shaft on transmission flange Clutch pressure line

Thread M12 M10 M10 M14 M12 M10 M10 M12 M10 M8 M10 M8 M14 M16 M10 M10

Tightening torque Nm (ftlb.) 85 (63) 65 (48) 81 (60) 130 (96) 110 (81) 65 (48) 65 (48) 110 (81) 23 (17) 23 (17) 46 (34) 23 (17) 25 5 (19 3.5) 30 + 5 (22 + 3.5) 10 + 5 (7.5 + 3.5) 46 (34) 30 (22)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques: Removing and installing engine

1182

24 40 20 Removing and installing injection valves Engine removed

Caution Removing injection valves of cylinder bank 1 3 Removing injection valves of cylinder bank 4 6 Installing injection valves of cylinder bank 1 3 Installing injection valves of cylinder bank 4 6 WARNING Observe the general safety instructions when working on the fuel system and when handling petrol and other fuels! => Precautionary measures when working on fuel system Note Observe installation position of peripheral 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

Removing injection valves of cylinder bank 1

1. Remove connectors of the injection valves. 2. Remove the cable duct from the fuel collection pipe. 3. Unscrew the 2 M6 hexagonhead bolts from the fuel collection pipe. 4. Carefully pull the fuel collection pipe upwards until the injection valves are free. 5. Pull out the tab washers A of the injection valves.

6. Carefully pull out the injection valves B . top of page

24 40 20 Removing and installing injection valves Engine removed

1183

einordnung

Removing injection valves of cylinder bank 4

Requirement: Remove the secondary air pump => Removing and installing secondary air pump. 1. Remove connectors of the injection valves. 2. Remove the cable duct from the fuel collection pipe. 3. Unscrew the 2 M6 hexagonhead bolts from the fuel collection pipe. 4. Carefully pull the fuel collection pipe upwards until the injection valves are free. 5. Pull out the tab washers of the injection valves A .

6. Carefully pull out the injection valves B . top of page

Installing injection valves of cylinder bank 1

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 sealing rings of the injection valves slightly with Vaseline. 2. Press the injection valves carefully into the cylinder head. 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 tighten the two M6 screws. Tightening torque 10 Nm (7.5 ftlb.) 6. Clip the cable duct to the fuel collection pipe. Removing injection valves of cylinder bank 4 6 1184

einordnung top of page

Installing injection valves of cylinder bank 4

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 sealing rings of the injection valves slightly with Vaseline. 2. Press the injection valves carefully into the cylinder head. 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 tighten the two M6 hexagonhead bolts. Tightening torque 10 Nm (7.5 ftlb.) 6. Clip the cable duct to the fuel collection pipe. 7. Install secondary air pump => Removing and installing secondary air pump.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing injection valves of cylinder bank 1

1185

24 40 20 Removing and installing injection valves Engine installed

Caution Preliminary work Removing injection valves of cylinder bank 1 Removing injection valves of cylinder bank 4 Installing injection valves

3 6

WARNING Observe the general safety instructions when working on the fuel system and when handling petrol and other fuels! => Precautionary measures when working on fuel system WARNING The battery must be disconnected when working on electrical components. top of page

Preliminary work
1. Read out the fault memory with the Porsche System Tester. 2. Find out the 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

Removing injection valves of cylinder bank 1

1. Pull off the connecting hoses between the charge air coolers and the Yshaped pressure pipe. To do this, unclip the retaining clips using a screwdriver and pull out the hose. Refit the retaining clips immediately. 2. Detach the holder over the airconditioning compressor. Unscrew the M6 screw on the holder for this purpose.

3. Undo the hose of the Yshaped pressure pipe. To do so, undo the hose clamp arrow and pull the hose off the Yshaped pressure pipe.

24 40 20 Removing and installing injection valves Engine installed

1186

einordnung

4. Remove the Yshaped pressure pipe. To do so, undo the hose clamps 3 and 5 and the hexagonhead bolts 1 and 2 . Pull off pressure sensor plug 4 . 5. Remove the threephase generator => Removing and installing threephase generator.

6. Remove box for connector. Unscrew the two M6 screws and lay the box to one side. 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 workshop jack. Undo the two hexagon nuts on the right and left of the engine mount. Lower engine by max. 30 mm 40 mm.

8. Undo the hose arrow on the left pressure pipe. To do so, undo the hose clamp and pull the hose arrow off the pressure pipe.

Removing injection valves of cylinder bank 1

1187

einordnung

9. Disconnect the connector of the overrun air valve module arrow and pull off the two vacuum hoses arrow .

10. Undo the hose clamp on the left pressure pipe and remove 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 the front intake pipe connector.

14. Remove hose clamp and pull off ventilation hose from the intake pipe.

Removing injection valves of cylinder bank 1

1188

einordnung

15. Undo the upper fastening screw right arrow . Lift the intake pipe out of the shaft bolt left arrow and remove towards the rear of the vehicle. Remove the seal.

16. Disconnect the activated carbon filter lead. To do so, disconnect the coupling arrow .

17. Pull off the connector 1 of the camshaft adjustment valve. Note With all fuel lines, always counter with a second openended wrench!

18. Disconnect the fuel return line 2 (a/f 14 and 17). Unscrew the M6 screw in the holder 3 . 19. Disconnect the fuel supply line 4 (a/f 17 and 19). 20. Disconnect the fuel line 5 (a/f 17 and 19) to the fuel collection pipe, cylinder bank 4 6. 21. Unclip the cable duct on the fuel collection pipe and lay it as far as possible to the side.

Removing injection valves of cylinder bank 1

1189

einordnung

22. Undo the fuel collection pipe. Unscrew the two M6 screws arrows on the fuel collection pipe for this purpose. 23. Remove connectors of the injection valves. 24. Carefully pull out the fuel collection pipe with the injection valves.

25. Pull off the tab washers of the injection valves A and pull the injection valve B out of the fuel collection pipe. top of page

Removing injection valves of cylinder bank 4

1. Remove rear right wheel housing liner. 2. Remove charge air cooler module. 3. Remove rear right heat insulation plate. 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! 4. Lower engine. Secure the engine against falling down with a workshop jack. Undo the two hexagon nuts on the right and left of the engine mount. Lower engine by max. 30 mm 40 mm. 5. Disconnect the connectors of the ignition coils of cylinders 5 and 6. 6. Pull off the connectors for the valve lift adjustment valve and the hall sender. 7. Remove the pressure hoses on the left and right of the Yshaped pipe to the charge air cooler. To do this, unclip the retaining clips using a screwdriver and pull out the hose. Refit the retaining clips immediately. 8. Detach the holder over the airconditioning compressor. Unscrew the M6 screw on the holder for this Removing injection valves of cylinder bank 4 6 1190

einordnung purpose.

9. Remove the Yshaped pressure pipe. To do so, undo the hose clamps 3 and 5 and the hexagonhead bolts 1 and 2 . Disconnect pressure sensor plug 4 .

10. Disconnect the connectors of the main wiring harness arrows in the 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 to one side.

13. Disconnect the fuel supply line 1 (a/f 19 and 22) and the fuel return line 2 (a/f 17 and 19). 14. Undo the cable duct at the fuel collection pipe.

Removing injection valves of cylinder bank 4

1191

einordnung

15. Undo the fuel collection pipe. Unscrew the two M6 screws 3 for this purpose. Note When removing the fuel collection pipe, lever it up very carefully and pay attention to all leads in order to avoid any damage!

16. First raise the fuel collection pipe carefully at cylinder 4, then at cylinder 6. 17. Raise the cable duct as far as possible, pull off the connectors of the injection valves and remove the fuel collection 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 injection valves. 2. Coat the sealing rings of the injection valves slightly with Vaseline.

3. Press the injection valves into the fuel collection pipe A and then install the tab washers B . Align the injection valves so that the lugs on the valves and the lugs on the fuel collection pipe lie directly above one another. Ensure that the tab washers are seated correctly. Installing injection valves 1192

einordnung Note When installing the fuel collection pipe, make sure that the injection valves are not damaged or soiled! 4. Place the fuel collection pipe with the injection valves of cylinder bank 4 6 in position on the right intake distributor. Connect connectors of the injection valves. 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 Nm (7.5 ftlb.) Note With all fuel lines, always counter with a second openended wrench!

6. Position and tighten the fuel supply line 1 (a/f 19 and 22). Tightening torque 30 Nm (22 ftlb.)

7. Connect the vacuum hose to the fuel pressure regulator.

Installing injection valves

1193

einordnung

8. Position and tighten the fuel return line 2 (a/f 17 and 19). Tightening torque 30 Nm (22 ftlb.) 9. Connect the cable duct to the fuel collection pipe. Ensure correct seating. 10. Connect hall sender connector.

11. Fit the connectors of the main wiring harness arrows in the engine compartment on the right. 12. Connect the connectors of the ingition coils of cylinder 5 and 6 and the connector of the valve lift adjustment 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 injection valves into the openings in the intake pipe.

14. Fasten the fuel collection pipe. Put on and tighten the two M6 screws arrows on the fuel collection pipe for this purpose. Tightening torque of M6 screws = 10 Nm (7.5 ftlb.) 15. Connect the cable duct to the fuel collection pipe. Ensure correct seating. Note With all fuel lines, always counter with a second openended wrench!

Installing injection valves

1194

einordnung

16. Position and tighten the fuel line 5 (a/f 17 and 19) to the fuel collection pipe, cylinder bank 4 6. Tightening torque 30 Nm (22 ftlb.)

17. Position and tighten the fuel supply line 4 (a/f 17 and 19). Tightening 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. Connect plug of camshaft adjuster 1 . Note In order to check the fuel system for leaks, the following operations must be carried out! 20. Install fuel filter. Installing injection valves 1195

einordnung

21. Connect together the plug connection of the activated carbon filter lead. The plug must engage audibly. Pull slightly to ensure that the connection is properly locked. Note None of the electrical connections of the threephase generator nor any of the other plug connections may come into contact with the body or any other components! 22. Install the B+ lead and the plug connection on the threephase generator. Lay the threephase generator aside. Make sure that the connections do not come 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 Tester and allow the pump to run for approx. 2 3 min. 26. Disconnect battery. 27. Remove the threephase generator. To do this, disconnect the B+ wire and the plug. 28. Remove fuel filter. 29. Install secondary air pump. 30. Install the rear right heat insulation plate. 31. Install charge air cooler module. 32. Install rear right wheel housing liner. 33. Insert new seal at the intake pipe connector.

34. Place the intake pipe in position on the shaft bolt left arrow .

Installing injection valves

1196

einordnung

35. Connect the vent hose. Tighten hose clamp arrow .

36. Position and tighten the three screws at the front 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 holder 3 . Tightening torque of M6 screw = 10 Nm (7.5 ftlb.)

Installing injection valves

1197

einordnung

39. Tighten the hose arrow on the left pressure pipe. To do so, push the hose arrow on and tighten the screwtype hose clamp.

40. Install the overrun air valve module Figure .

41. Connect the connector of the overrun air valve module arrow and push on the two vacuum hoses arrow . 42. Install fuel filter 20 60 55 Installing fuel filter . 43. Connect the 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 the tighten both the collar nuts. Tightening torque of collar nuts 85 Nm (63 ftlb.)

45. Install box for connector. Put on and tighten the two M6 screws arrows for this purpose. Tightening torque of M6 screws = 10 Nm (7.5 ftlb.) 46. Install threephase generator 27 22 19 Installing the threephase generator .

Installing injection valves

1198

einordnung

47. Press the Yshaped pressure pipe into the air cowl of the throttle body, connect the hoses 3 and 5 and fasten the hose clamps. Connect the connector of the pressure sensor 4 and position and tighten the M6 screws 1 and 2 . Tightening torque of M6 screws = 10 Nm (7.5 ftlb.) 48. Install the holder over the airconditioning compressor. Position and tighten the M6 screw in the holder for this purpose. Tightening torque of M6 screw = 10 Nm (7.5 ftlb.)

49. Connect hose to the Yshaped pipe and fasten with the hose clamp arrow . 50. Install the connecting hoses between the charge air coolers and the Yshaped pressure pipe; the connecting hoses must engage audibly. 51. Install air cleaner housing => Removing and installing air cleaner. 52. Install rear spoiler 63 55 19 Installing rear spoiler . 53. Connect the battery. 54. Read out the fault memory with the Porsche System Tester. 55. Enter radio code. 56. Perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing injection valves

1199

24 69 19 Removing and installing oxygen sensors in front of catalytic converter

Tools Removing oxygen sensors in front of catalytic converter Installing oxygen sensors in front of catalytic converter top of page

Tools

Item Designation of the tool Open ring wrench for oxygen sensor Hazet 46813

Remarks Gr. 2.4; No. 98 Workshop Equipment Manual Torque wrench 1/2 " Wille 730 R/12 or Torque wrench 1/2 Gr. 2.4; No. 90 Workshop " Hazet 62911CT Equipment Manual

top of page

Removing oxygen sensors in front of catalytic converter

24 69 19 Removing and installing oxygen sensors in front of catalytic converter

1200

einordnung

Illustration shows 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

Oxygen sensor plug 1 Plug for sensor in front of catalytic converter with plastic clip (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 air cleaner

2. Separate the rectangular plug connection for the oxygen sensor in front of the catalytic converter in the left engine compartment 1 . To do this, first open the plastic securing clip. Removing oxygen sensors in front of catalytic converter 1201

einordnung 3. Unclip the oxygen sensor wire in front of the catalytic converter from the wire retainer and the sheetmetal clips. Note Always expose oxygen sensor wire so that the wire can turn when unscrewing the 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 rectangular plug connection for the oxygen sensor in front of the catalytic converter 1 . To do this, first open the plastic 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 unscrewing the sensor. 4. Undo and unscrew oxygen sensor with a spanner or an open ring wrench (a/f 22). top of page

Installing oxygen sensors in front of catalytic converter

The oxygen sensor is installed in reverse sequence. Note Always expose oxygen sensor wire so that the wire can turn when screwing in the sensor. 1. Position the oxygen sensor by hand and screw in as far as possible. 2. Tighten oxygen sensor with conventional open ring wrench Hazet 46811 and torque wrench.

Oxygen sensor, left side :

1202

einordnung

Oxygen sensor in front of catalytic converter on left side

Oxygen sensor in front of catalytic converter on right side Tightening torque: 55 5 Nm (41 4.0 ftlb.) 3. Lay oxygen 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 and installing air cleaner.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing oxygen sensors in front of catalytic converter

1203

24 70 19 Removing and installing DME control module

Obtaining readout and saving vehicle data from DME control module Removing DME control module Installing 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 DME control module GT2 and version X51 Version (data records) 911 Turbo (996) Version (data records) GT2

24 70 19 Removing and installing DME control module

1204

einordnung Note If the DME control module is replaced, it must be programmed using the Porsche System Tester. Thus, the DME control module can be adapted to the vehicle, the national variant and the equipment. The DME control module is located behind the right rear seat. If possible, before the DME control module is removed and replaced, a readout of the vehicle data should be obtained from the Porsche System Tester. Symbol for the TAB key = | Follow the instructions for the Porsche System Tester.

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Obtaining readout and saving vehicle data from DME control module
1. Connect the Porsche System Tester to the vehicle and start the System Tester. 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. 5. Select "Control unit programming" with the cursor keys and press the >> key. 6. Select "Readout control unit (vehicle data)" with the cursor keys and press the >> key. 7. The message "Vehicle data readout complete" will appear on the screen of the Porsche System Tester. 8. After replacement of the DME control module, the vehicle data is installed in the menu "Program control unit" (see Section 6). top of page

Removing DME control module

Note Switch ignition off and remove ignition key. 1. Fold the backrests of the rear seats forward. 2. Lift the carpet lining up and remove.

Obtaining readout and saving vehicle data from DME control module

1205

einordnung

3. Unscrew fastening screw 1 and loosen fixing nut 2 . 4. Turn over the control module holder 3 .

5. Push in connectors A arrow and pull out. 6. Push in locking element arrow of connectors B and actuate the latching lever 4 . 7. Unscrew 4 fastening screws 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. Tightening torque: 10 Nm (7.5 ftlb.). 2. Push in connectors B on the DME control module and close the latching lever 4 until the lever engages. 3. Press in plugs A on the control module, until they engage.

Removing DME control module

1206

einordnung

4. Turn over the control module holder 3 and push it in under the fastening nut 2 . Tighten both fastening screws 1 and the fastening nut 2 . Tightening torque: 10 Nm (7.5 ftlb.). 5. Place carpet lining in position, paying attention to the fitted shape. 6. Program the DME control module with the Porsche System Tester. => 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 DME control module GT2 and version X51 top of page

Programming the new DME control module 911 Turbo (996)

Note If a new DME control module is to be installed in a vehicle, the 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. 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 instructions for the Porsche System Tester. 1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch ignition on. 2. Select vehicle type using the cursor keys. In the 911 Turbo 911 (996). 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. 5. Select "Control unit programming" with the cursor keys and press the >> key. 6. Select "Control unit programming with the cursor keys and press the >> key. Follow the displayed programming instructions from the Porsche System Tester. 7. Enter the Veh. Ident. No. with the cursor keys, continue with >> and confirm with F7. 8. Enter the new DME (IPAS) programming code and confirm with the >> key. 9. Check the DME programming code again; if the code is correct, confirm with the F7 key. 10. Installing the DME control module 1207

einordnung Enter the new immobilizer code (IPAS), confirm with the >> key, check the code again and confirm with the F7 key. 11. Select the required program map and confirm with the >> key. => Version (data records) 911 Turbo (996) 12. The data and programming status is then loaded on to the DME control module. Do not interrupt the programming sequence. 13. When the programming period has expired, follow the instructions from the Porsche System Tester CAN TIME OUT . 14. Press the >> key. For the learning and adaptation routine of the throttle (Egas), switch the ignition on for 1 minute without starting the engine and without actuating the accelerator pedal. Then switch the ignition off for at least 10 seconds. This completes the adaptation of the throttle adjusting unit and the programming sequence is complete. 15. Read out the fault memory and delete the fault CAN TIME OUT on every control unit that is connected to the CAN. top of page

Programming the new DME control module GT2 and version X51
Note If a new DME control module is to be installed in a vehicle, the 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. In the case of the GT2, a Key 1 code is displayed in the Porsche System Tester (see Point 12); in addition, a Key 2 code is required (see Point 15) in order to be able to transfer the data status required for this vehicle type. 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. Determine the Key 1 code by following the described procedure and finish with << . After receiving the Key 2 code, begin again at Point 1. It is possible to program a GT2 DME control module as from Porsche System Tester Version 11.1. Symbol for the TAB key = | Follow the instructions for the Porsche System Tester. 1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch ignition on. 2. Select vehicle type GT2 using the cursor keys. 3. Using the | key, move from the vehicle type to the list of control modules. 4. Select DME with the cursor keys and press the >> key. Programming the new DME control module 911 Turbo (996) 1208

einordnung 5. Select Control unit programming with the cursor keys and confirm with the >> key. 6. Select "Control unit programming with the cursor keys and press the >> key. Follow the displayed programming instructions from the Porsche System Tester. 7. Enter the Veh. Ident. No. with the cursor keys and confirm. 8. Enter the new DME (IPAS) programming code and confirm with the >> key. 9. Check the DME programming code again; if the code is correct, confirm with the F7 key. 10. Enter the new immobilizer code (IPAS), check it again and confirm with F7. 11. Select the required program map and confirm with the >> key => Version (data records) GT2 12. With the GT2, a Key 1 code is displayed in the Tester, which is automatically stored in the release protocol. 13. With the ALT key (Hard copy), move into the Printer menu, select the release protocol and print it out. 14. The name and telephone number of the contact person must be noted on the release protocol. Fax the protocol to Porsche AG, Dept. VAC1, fax no. 0049/711/9118570. 15. A Key 2 code is then delivered to you by Dept. VAC1. Enter the Key 2 code with the cursor keys, continue with the >> key and, after checking the Key 2 code, confirm it with the F7 key. 16. The data and programming status is then loaded on to the DME control module. Do not interrupt the programming sequence. 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 (Egas), switch the ignition on for 1 minute without starting the engine and without actuating the accelerator pedal. Then switch the ignition off for at least 10 seconds. This completes the adaptation of the throttle adjusting unit and the programming sequence is complete. 19. Read out the fault memory and delete the fault CAN TIME OUT on every control unit that is connected to the CAN. top of page

Programming the DME control module 911 Turbo (996)

Note If the DME control module from a different 911 Turbo (996) vehicle is being used, proceed as follows. As a check, the DME code and the immobilizer code of the vehicle in which the control module is being installed (NEW) and of the vehicle from which the control module has been removed (OLD) are required. You can get the necessary codes from IPAS or from your importer by specifying the vehicle identification number. 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 = | When programming maps, update the data records. Procedure is similar to Control unit programming . Follow the instructions from the Porsche System Tester => Version (data records) Programming the new DME control module GT2 and versionX51 1209

einordnung 911 Turbo (996). 1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch ignition on. 2. Select vehicle type using the cursor keys. In the 911 Turbo 911 (996). 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. 5. Select "Control unit programming" with the cursor keys and press the >> key. 6. Select "Control unit programming with the cursor keys and press the >> key. Follow the displayed programming instructions from the Porsche System Tester. 7. Enter the Veh. Ident. No. with the cursor keys, continue with >> and confirm with F7. 8. Enter the old 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, continue with the >> key and, after checking, confirm with F7. 10. Enter the old immobilizer code (IPAS, vehicle OLD), continue with the >> key, check the code again and confirm with F7. 11. Enter the new immobilizer code (IPAS, vehicle NEW), continue with the >> key, check the code again and confirm with F7. 12. Select 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 the programming period has expired, follow the instructions from the Porsche System Tester CAN TIME OUT . 15. Press the >> key. For the learning and adaptation routine of the throttle (Egas), switch the ignition on for 1 minute without starting the engine and without actuating the accelerator pedal. Then switch the ignition off for at least 10 seconds. This completes the adaptation of the throttle adjusting unit and the programming sequence is complete. 16. Read out the fault memory and delete the fault CAN TIME OUT on every control unit that is connected to the CAN. top of page

Programming DME control module GT2 and version X51

Note X51 increased performance. If the DME control module from a different GT2 vehicle is being used, proceed as follows. As a check, the DME code and the immobilizer code of the vehicle in which the control module is being installed (NEW) and of the vehicle from which the control module has been removed (OLD) are required. You can get the necessary codes from IPAS or from your importer by specifying the vehicle identification number.

Programming the DME control module 911 Turbo (996)

1210

einordnung 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. In the case of the GT2, a Key 1 code is displayed in the Porsche System Tester (see Point 13); in addition, a Key 2 code is required (see Point 16) in order to be able to transfer the data status required for this vehicle type. Determine the Key 1 code by following the described procedure and finish with << . After receiving the Key 2 code, perform the following instruction. It is possible to program a GT2 DME control module as from Porsche System Tester Version 11.1. Symbol for the TAB key = | When programming maps, update the data records. Procedure is similar to Control unit programming . Follow the instructions from the Porsche System Tester => Version (data records) GT2. 1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch ignition on. 2. Select vehicle type GT2. 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. 5. Select "Control unit programming" with the cursor keys and press the >> key. 6. Select "Control unit programming with the cursor keys and press the >> key. Follow the displayed programming instructions from the Porsche System Tester. 7. Enter the Veh. Ident. No. with the cursor keys, continue with >> and confirm with F7. 8. Enter the old 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, continue with the >> key and, after checking, confirm with F7. 10. Enter the old immobilizer code (IPAS, vehicle OLD), continue with the >> key, check the code again and confirm with F7. 11. Enter the new immobilizer code (IPAS, vehicle NEW), continue with the >> key, check the code again and confirm with F7. 12. Select the required program map and confirm with the >> key. => Version (data records) GT2 13. With the GT2, a Key 1 code is displayed in the Tester, which is automatically stored in the release protocol. 14. With the ALT key (Hard copy), move into the Printer menu, select the release protocol and print it out. 15. The name and telephone number of the contact person must be noted on the release protocol. Fax the protocol to Porsche AG, Dept. VAC1, fax no. 0049/711/9118570. 16. A Key 2 code is then delivered to you by Dept. VAC1. Enter the Key 2 code with the cursor keys, continue with the >> key and, after checking the Key 2 code, confirm it with the F7 key. 17. The data status is loaded on to the DME control module. Do not interrupt the programming sequence. 18. When the programming period has expired, follow the instructions from the Porsche System Tester CAN TIME OUT . 19. Press the >> key. For the learning and adaptation routine of the throttle (Egas), switch the ignition on for 1 minute without starting the engine and without actuating the accelerator pedal. Programming DME control module GT2 and version X51 1211

einordnung Then switch the ignition off for at least 10 seconds. This completes the adaptation of the throttle adjusting unit and the programming sequence is complete. 20. Read out the fault memory and delete the fault CAN TIME OUT on every control unit that is connected to the CAN. top of page

Version (data records) 911 Turbo (996)

Note The table shown is included in the software status 11.0, Porsche System Tester 2. Later software versions may feature expanded contents. Under the heading DME, Control unit programming, Control unit type it is possible to check whether the data record for this vehicle is uptodate or not. In the case of Not uptodate the data record can be updated with Program map . The prerequisite 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 Uptodate the data record and the version are displayed.

Type/Diagnosis software no. M 150/2201

Version

Remarks Countries with leaded fuel

Manual transmission Tiptronic EOBD/Japan/Australia Manual transmission Tiptronic EOBD/2301 Manual transmission Tiptronic OBD II/2101 LEV, manual transmission LEV, Tiptronic X51/M 150/5301 Manual transmission Tiptronic X51/EOBD/Japan/Australia Manual transmission Tiptronic X51/EOBD/5401 Manual transmission

European OnBoard Diagnosis. Rest of the world vehicles, including Europe (EU 3) For Japan/Australia. European OnBoard Diagnosis. Rest of the world vehicles, including Europe (EU 3) and Germany (EU 3/D4). Low Emission Vehicle, USA

Countries with leaded fuel

European OnBoard Diagnosis. Rest of the world vehicles, including Europe (EU 3) For Japan/Australia. European OnBoard Diagnosis. Rest of the world vehicles, including Europe (EU 3) and Germany (EU

Version (data records) 911 Turbo (996)

1212

einordnung Tiptronic Manual transmission Tiptronic 3/D4). Low Emission Vehicle, USA

X51/OBD II/5201

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Version (data records) GT2

Note The table shown is included in the software status 12.0, Porsche System Tester 2. Later software versions may feature expanded contents. Under the heading DME, Control unit programming, Control unit type it is possible to check whether the data record for this vehicle is uptodate or not. In the case of Not uptodate the data record can be updated with Program map . The prerequisite 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 Uptodate the data record and the version are displayed.

Type/Diagnosis software version no. GT2/5601 model '01 5901 as from model '02 GT2 00/EOBD 5501 model '01 5801 as from model '02 GT2/EOBD 5501 model '01 5801 as from model '02 GT2/OBD II 5701 as from model '02

Version M 150 EU 3

Remarks Countries with leaded fuel Japan/Australia

EU 3

Rest of the world vehicles, including Europe (EU 3) and Germany (EU 3/D4) Low Emission Vehicle, USA

LEV

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Version (data records) GT2

1213

27 60 19 Removing and installing starter (automatic transmission)

Removing the starter Installing the starter top of page

Removing the starter

1. Disconnect the battery and cover terminal or battery. 2. Disengage the parking brake cable from the left side behind the parking brake lever and push it back into the guide. 3. Remove the cover under the automatic transmission. 4. Undo the cross member (2 screws M10) and pull the parking brake cable out of the guide. 5. Disengage both the coolant lines for the heating under the automatic transmission (3 plastic holders).

6. Detach 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 transmission mount and allow them to hang down. 9. Pull back protective cap on the solenoid switch and undo terminal 30 lead (M8 nut) and terminal 50 (M6 nut). 10. Pull protective cap off the B+ lead. In order to undo the fastening screws, use a 3/8inch tool. 11. Undo the upper M10 fastening screw. Tools: Hexagon socket wrench insert a/f 15 Short extension, approx. 130 mm long Universal joint 2 long extensions Cross handle or ratchet 12. Undo the lower M10 fastening screw. Tools: Hexagon socket wrench insert a/f 15 27 60 19 Removing and installing starter (automatic transmission) 1214

einordnung Universal joint 2 long extensions Cross handle or ratchet 13. Press the coolant hoses to one side and carefully remove the starter downwards from the holder. top of page

Installing the starter

1. Install and fasten starter. Fasten B+ lead from the battery and B+ lead from the engine B+ disconnection point to terminal 30 (M8 nut) on the solenoid switch. 2. Fasten terminal 50 lead (M6 nut) to the solenoid switch. Tightening torque for M8 hexagon nut: 15 Nm (11 ftlb.), M6 screw: 6.5 Nm (5 ftlb.) Tightening torque of the hexagonhead bolt M10: 46 Nm (34 ftlb.) 3. Push protective cap over the solenoid switch and engage in the B+ lead. 4. Fasten the sheetmetal holder on the transmissioin flange lid and engage the plastic holder. 5. Fasten the coolant lines under the automatic transmission and install the cross member. 6. Install the parking brake cable and fasten the cover under the automatic transmission. 7. Connect the battery and perform a function test.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Removing the starter

1215

34 35 37 Partially disassembling transmission

Note Tools Removing transmission cover Disassembling front gear set Removing gear housing Removing input and output shaft Dismantling input shaft Note If the transmission to be opened is still 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.

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Tools

Item A B

Special tool designation Socket wrench insert Socket wrench insert

Remarks Special tool socket wrench insert 9105 Commercially available; refer to Workshop Equipment Manual, Chapter 2.4, No. 64 1216

34 35 37 Partially disassembling transmission

einordnung C D E F G H J Retaining device Socket wrench insert Pressure piece Twoarmed extractor, span 250 Special tool retaining device 9253 Special tool socket wrench insert 9282 Special toolpressure piece 9656 Commercially available; refer to Workshop Equipment Manual, Chapter 2.4, No. 103 Separator 17 75 cm Commercially available; refer to Workshop Equipment Manual, Chapter 2.4, No. 109 Twoarmed extractor, span 120 Commercially available; refer to Workshop Equipment Manual, Chapter 2.4, No. 101 Puller hook, 400 mm long Commercially available; refer to Workshop Equipment Manual, Chapter 2.4, No. 105

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Removing transmission cover

1. Remove transmission 34 35 27 Removing and refitting the transmission. 2. Fasten the transmission on assembly support. 3. Drain transmission oil 34 01 55 Changing transmission oil. 4. Fix the transmission with special tool retaining device 9253 and shift into a gear. 5. Unscrew the fastening nut for the cardan shaft flange with a commercially available socket wrench insert Workshop Equipment Manual, Chapter 2.4, No. 64 . 6. If necessary force cardan shaft flange off with a rubber hammer. 7. Unscrew fastening screws for front transmission case cover and force transmission case cover off with a rubber hammer if necessary. top of page

Disassembling front gear set

Overview

Tools

1217

einordnung

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Designation Sleeve Hexagon nut (selflocking) Cylindricalroller bearing Thrust plate Loose gearwheel, reverse gear Synchronising ring Needleroller bearing Bearing inner race Shift collar Washer Hexagonhead bolt Shift fork (reverse gear) Spring

Qty. 1 1 1 1 1 1 1 1 1 2 2 1 3 1218

Overview

einordnung 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Ball Driver dog Guide sleeve with snap ring Loose gearwheel, 5th gear Synchronising ring Needleroller bearing Bearing inner race Shift collar Driver dog Ball Spring Guide sleeve Shift fork (5th and 6th gears) Synchronising ring Loose gearwheel, 6th gear Needleroller bearing Bearing inner race Thrust plate Hexagon nut (selflocking) Bearing inner race Fixed gearwheel, reverse gear Spacer sleeve Fixed gear wheel, 5th gear Spacer sleeve Fixed gearwheel, 6th gear Housing 3 3 1 1 1 1 1 1 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Disassembling gear set

Note All needleroller bearings which are not replaced must be designated in terms of the installation position and allocation to the gear wheel. 1. Remove transmission cover.

Disassembling gear set

1219

einordnung

2. Remove nut A on input and output shaft. 3. Unscrew clamping screw from shift forks B . 4. Remove fixed gearwheel for reverse gear (no. 34 in overview) from the input shaft using the puller and special tool pressure pieces 9656 . When doing so, pull off bearing inner race (no. 33 in overview). 5. Remove spacer sleeve (no. 35 in overview) from the input shaft. 6. Remove loose gearwheel for reverse gear (no. 5 in overview) with needleroller bearing (no. 7 in overview) from the output shaft using the puller. When doing so, also pull off the cylindricalroller bearing (no. 3 in overview) and thrust plate (no. 4 in overview). 7. Push complete gear set forwards onto output shaft using two mounting levers 1 2 cm. 8. Push gear set back behind the bearing inner race (no. 8 in overview) and remove bearing inner race using 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 overview) and the spacer sleeve (no. 35 in overview). 11. Remove loose gearwheel, 5th gear (no. 17 in overview) with needleroller bearing (no. 19 in overview). 12. Remove bearing inner race (no. 20 in overview) using the puller. 13. Open up shift fork and remove complete synchonization. 14. Remove loose gearwheel, 6th gear (no. 28 in overview) with needleroller bearing (no. 29 in overview). 15. Press the bearing inner race (no. 30 in overview) forwards with the mounting lever and remove using the puller. 16. Remove thrust plate (no. 31 in overview). top of page

Removing gear housing

1. Remove transmission cover. 2. Disassemble front gear set. 3. Unscrew fastening screws between the gear housing and the transmission.

4. Unscrew plug screw A and remove the spring with locking pins. Removing gear housing 1220

einordnung 5. If necessary force gear housing off with a rubber hammer. top of page

Removing input and output shaft

Overview

No. 1 2 3 4

Designation Cylindricalroller bearing Thrust plate Loose gear wheel, 1st gear Friction ring

Qty. 1 1 1 1 1221

Removing input and output shaft

einordnung 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Tapered ring Synchronising ring Needleroller bearing Bearing inner race Shift collar Guide sleeve Driver dog Ball Spring Synchronising ring Tapered ring Friction ring Loose gear wheel, 2nd gear Needleroller bearing Bearing inner race Thrust plate 3rd gear fixed gear wheel Locking element Shift rod (1st/2nd gear) Intermediate locking element Shift rod (reverse gear) Selector shaft Shift rod (5th/6th gear) Tensioning plate Hexagon nut Shift rod (3rd/4th gear) Cylindricalroller bearing Screw plug Spring Ball Adjusting shim S3 Spacer sleeve Fixed gearwheel, 4th gear Transmission housing 1 1 1 1 1 1 3 3 3 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 7 1 1 4 4 4 X 1 1 1

Removing shafts
1. Unscrew screw plugs (no. 32 in overview) of the locking elements and remove springs (no. 33 in overview) and ball (no. 34 in overview). 2. Pull out reverse gear shift rod (no. 25 in overview) and shift rods for 5th/6th gear (no. 27 in overview) towards the front. Pay attention to the intermediate lock (no. 24 in overview) and locking elements (no. 22 Overview 1222

einordnung in overview) during this procedure. 3. Remove differential lock 39 40 19 Removing and installing differential and differential lock. 4. Remove cylindricalroller bearing (no. 31 in overview) from input shaft using a puller. 5. Pull loose gearwheel for 1st gear (no. 3 in overview) off the input shaft with the thrust plate (no. 2 in overview) and cylindricalroller bearing (no. 1 in overview). 6. Pull off the fixed wheel for 3rd gear (no. 21 in overview) 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 synchronisation in assembled state may be recommendable as loss of the small parts can then be avoided. 8. Unscrew nuts (no. 29 in overview) and remove tensioning plate (no. 28 in overview) with shafts and remaining gear wheels. 9. Remove spacer sleeve (no. 36 in overview) and fixed wheel for 4th gear (no. 37 in overview) and take output shaft out of the tensioning plate. top of page

Dismantling input shaft

Overview

Removing shafts

1223

einordnung

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Designation Hexagon nut (selflocking) Cylindricalroller bearing Bearing inner race Fourpoint bearing Tensioning plate Bearing inner race Shift rod / 3rd/4th gear shift fork Locking element Thrust plate Loose gear wheel, 4th gear Synchronising ring Needleroller bearing Bearing inner race

Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1224

Overview

einordnung 14 15 16 17 18 19 20 21 22 Guide sleeve Shift collar Driver dog Ball Spring Synchronising ring Loose gear wheel, 3rd gear Needleroller bearing Input shaft 1 1 3 3 3 1 1 1 1

Disassembling 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 synchronisation (no. 11 to 19 in overview), loose gearwheel for 4th gear (no. 10 in overview) and the remaining parts (nos. 2 to 9 in overview).

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Disassembling shaft

1225

34 35 37 Assembling transmission
Note Tools Assembling input shaft Installing input and output shaft Fitting gear housing Assembling front gear set Fitting front transmission case cover Note If the transmission to be opened is still 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.

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Tools

Item A B C

Special tool designation Retaining device Socket wrench insert Socket wrench insert

Remarks Special tool retaining device 9253 Special tool socket wrench insert 9282 Special tool socket wrench insert 9105 1226

34 35 37 Assembling transmission

einordnung

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Assembling input shaft

Assembling shafts
Note The overview diagram of the input shaft is provided in the chapter Disassembling transmission under => Overview. 1. Clamp shaft with special tool socket wrench insert 9282 in the vice.

2. Assemble synchronization if necessary. The synchronization consists of parts 19 to 14 and 11 in the overview. Pay attention to correct seating of the synchronising rings A and 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 gear wheels and measure the gap A with a feeler gauge. Installation dimension (new): min. 0.9 mm Wear dimension: 0.6.....0.7 mm

Note Gear wheels may only be replaced in pairs. Always employ used needleroller bearings with the same gear wheel and in the same running direction. 4. Push needleroller bearing (no. 21 in overview), 3rd gear loose gearwheel (no. 20 in overview) and synchronisation onto input shaft. Tools 1227

einordnung 5. Heat bearing inner race (no. 13 in overview) to 120C and push onto input shaft. 6. Push 4th gear loose gearwheel (no. 12 and 10 in overview) and thrust plate (no. 9 in overview) onto input shaft. The large flatground side of the thrust plate faces towards the loose gearwheel (4th gear). 7. Heat bearing inner race (no. 6 in overview) to 120C and push onto input shaft. 8. Fit clamping plate with short lock (no. 5 and 8 in overview), fourpoint bearing (no. 4 in overview) and shift fork (no. 7 in overview) onto input shaft. 9. Heat bearing inner race (no. 3 in overview) to 120C and push onto input shaft. 10. Heat cylindricalroller bearing (no. 2 in overview) to 120C and push onto input shaft. 11. Screw new hexagon nut onto input shaft. Tightening torque: 250 Nm (185 ftlb.)

Tightening torques

Location Hexagon nut

Thread M30 x 1.5

Tightening torque Nm (ftlb.) 250

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Installing input and output shaft

Installing shafts
Note An overview diagram of the installation is provided in the chapter Disassembling transmission under => Overview. 1. Insert output shaft A with adjusting shim S5 B and adusting shim S4 C into tensioning plate F .

2. Push 4th gear fixed wheel D onto output shaft. The large collar faces the tensioning plate. 3. Push on the spacer sleeve E .

Assembling shafts

1228

einordnung

4. Affix adusting shim S3 A in the transmission case with viscous grease. 5. Insert input and output shaft into the transmission case with tensioning plate and tighten nuts. Tightening torque: 25 Nm (19 ftlb.) 6. Push on 3rd gear fixed gear (no. 21 in overview) onto the output shaft. The large collar faces the thrust plate (no. 20 in overview). 7. Push thrust plate onto the output shaft. 8. Heat bearing inner race (no. 19 in overview) to 120C and push onto output shaft. 9. Push needleroller bearing (no. 18 in overview) onto bearing inner race.

10. Check synchronisation of 2nd gear. To do so, place the friction 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 again in the same way for 1st gear. Installation dimension (new): 1.5 to 2.0 mm Wear dimension: 1.2 mm 11. Push 2nd gear loose gearwheel (no. 17 in overview) onto needleroller bearing. 12. Insert friction ring (no. 16 in overview), tapered ring (no. 15 in overview) and synchronisation ring (no. 14 in overview) into the guide sleeve (no. 10 in overview) and push onto output drive. In doing so, the recess of the inner toothing of the guide sleeve must align with the oil bore of the output shaft. 13. Heat bearing inner race (no. 8 in overview) to 120C and push onto output shaft.

14. Installing shafts 1229

einordnung Fit shift collar (no. 9 in overview) with shift rod for 1st/2nd gear (no. 23 in overview). The turned groove A in the shift collar must face the 2nd gear loose wheel. Note The dotting marks on the shift collar must be centred with 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 Shift collar 2 Ball 3 Driver dog 4 Spring A Recognition groove B Dotting mark C 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. 17. Fit the synchronising ring (no. 6 in overview), the tapered ring (no. 5 in overview) and the friction ring (no. 4 in overview). 18. Push needleroller bearing (no. 7 in overview) onto bearing inner race. 19. Push 1st gear loose gearwheel (no. 3 in overview) and thrust plate (no. 2 in overview) onto output shaft. 20. Heat cylindricalroller bearing (no. 1 in overview) to 120C and push onto output shaft. 21. Heat cylindricalroller bearing (no. 31 in overview) to 120C and push onto input shaft.

Installing shafts

1230

einordnung

22. Fit shift rods, selector shaft and locking elements. Affix locking elements with viscous grease if necessary. Ensure that that the rollers on the selector shaft are complete. 1 Shift rod for 3rd/4th gear 2 Locking element (short) 3 Shift rod for 5th/6th gear 4 Intermediate locking element 5 Locking element (long) 6 Reverse gear shift rod 7 Intermediate 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 neutral lock or gear lock during or after fitting as otherwise the small locking elements and the balls of the lock can fall into the transmission.

Tightening torques

Location Tensioning plate on transmission case Screw plug locking element

Thread M 8 x 45 M 10 x 1

Tightening torque Nm (ftlb.) 25 (19) 15 (11)

top of page

Tightening torques

1231

einordnung

Fitting gear housing

Fitting housing
1. Coat gear housing with Loctite 574 and put it on. To do this, insert shift rods into suitable bearing locations and ensure correct engaging of the shift catch roller in the driver of the selector shaft. 2. Screw in fastening screws. Tightening torque: 23 Nm (17 ftlb.) 3. Fit locking pin, spring and screw plug. Tightening torque: 25 Nm (19 ftlb.)

Tightening torques

Location Fastening screws, gear housing Screw plug

Thread M8 M 18 x 1.5

Tightening torque Nm (ftlb.) 23 (17) 25 (19)

top of page

Assembling front gear set

Note The overview diagram of the front gear set is provided in the chapter Disassembling transmission under => Overview.

Assembling gear set

1. Place thrust plate (no. 31 in overview) onto output shaft. 2. Heat bearing inner race (no. 30 in overview) to 120C and place on output shaft. 3. Place fixed gear for 6th gear (no. 38 in overview) onto the input shaft. The large collar faces the spacer sleeve (no. 37 in overview). 4. Place spacer sleeve (no. 37 in overview) onto input shaft.

Fitting gear housing

1232

einordnung

5. Check the synchronising rings for wear. To do this, push the synchronising rings onto the gear wheels and measure the gap A with a feeler gauge. Installation dimension (new): min. 0.9 mm Wear dimension: 0.6.....0.7 mm 6. Place loose gearwheel for 6th gear (no. 28 in overview) with needleroller bearing (no. 29 in overview) onto output shaft.

7. Assemble synchronisation (nos. 27, 25 to 21 and 18 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. 26 in overview) onto output shaft. 9. Heat bearing inner race (no. 20 in overview) to 120C and place on output shaft. 10. Place loose gearwheel for 5th gear (no. 17 in overview) with needleroller bearing (no. 18 in overview) onto output shaft. 11. Place fixed wheel for 5th gear (no. 36 in overview) onto the input shaft. The large collar faces the spacer sleeve (no. 37 in overview). 12. Place spacer sleeve (no. 35 in overview) onto input shaft. 13. Assemble synchronisation (nos. 16 to 13 and 9 in overview). Note The dotting marks on the shift collar must be centred with respect to the recesses in the guide sleeve.

Assembling gear set

1233

einordnung

14. Check the synchronising ring for wear. To do this, press synchronising ring onto the gear wheels and measure the gap A with a feeler gauge. Installation dimension (new): min. 0.9 mm Wear dimension: 0.6.....0.7 mm 15. Place synchronisation with shift fork (no. 12 in overview) onto output shaft. 16. Heat bearing inner race (no. 8 in overview) to 120C and place on output shaft. 17. Place loose gearwheel for reverse gear (no. 5 in overview) with needleroller bearing (no. 7 in overview) and synchronisation ring (no. 6 in overview) onto output shaft. 18. Place fixed gearwheel for reverse gear (no. 34 in overview) onto input shaft. 19. Heat bearing inner race (no. 33 in overview) to 120C and place on input shaft. 20. Tighten new selflocking 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 cylindricalroller bearing (no. 3 in overview) to 120C and place on output shaft. 23. Tighten new selflocking nuts (no. 2 in overview) on output shaft. Tightening torque: 300 Nm (222 ftlb.) 24. Adjust shift forks (nos. 26 and 12 in overview). The shift collar must have slight play in both directions in idle position. 25. Secure shift forks with screws and washers (nos. 10 and 11 in overview). Tightening torque: 18 Nm (13 ftlb.) 26. Remove special tool retaining device 9253 . 27. Shift through all gears as a test.

Tightening torques

Location Nuts on output shaft Nuts on input shaft Shift fork screws

Thread M 30 x 1.25 M 22 x 1.5 M8

Tightening torque Nm (ftlb.) 300 (222) 200 (148) 18 (13)

top of page Tightening torques 1234

einordnung

Fitting front transmission case cover

Fitting cover
1. Coat front transmission case cover with Loctite 574, put on and screw in fastening screws. Tightening torque: 23 Nm (17 ftlb.) 2. Imprint the letter R after the transmission number (only on transmissions 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 transmission.

Tightening torques

Location Fastening screws, front transmission case cover

Thread M8

Tightening torque Nm (ftlb.) 23 (17)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Fitting front transmission case cover

1235

35 50 19 Removing and installing sealing ring for input shaft

Tools Removing sealing ring for input shaft Installing sealing ring for input shaft Tightening torques top of page

Tools

Item 1 2 3

Special tool designation Pressure piece 9256 Assembly sleeve 9255 Puller 9629

Remarks

top of page

Removing sealing ring for input shaft

1. Remove enginetransmission unit and remove the transmission => Removing and refitting the transmission. 2. Remove guide tube for release bearing.

35 50 19 Removing and installing sealing ring for input shaft

1236

einordnung

3. Screw puller 9629 securely into the sealing ring. Note The coil spring must 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 hexagonhead screw. top of page

Installing sealing ring for input shaft

Removing sealing ring for input shaft

1237

einordnung

1. Push assembly sleeve 9255 onto the toothing of the input shaft. 2. Fill the space between the dust and sealing lips on the sealing ring with grease (e.g. LiquiMoly).

3. Drive in sealing ring with pressure piece 9256 as far 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 microencapsulated, therefore replace screws entirely. 5. Clean teeth of the input shaft and grease with a thin coat of Olista Longtime 3 EP (only as corrosion protection). top of page

Tightening torques

Location Guide tube for release bearing on transmission housing Installing sealing ring for input shaft

Thread M6x14

Tightening torque Nm (ftlb.) 10 1238

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

1239

37 04 19 Removing and installing selector knob

Removing selector knob Installing selector knob top of page

Removing selector knob

1. Lever the locking button A off with a suitable tool or finger. The locking button must be pressed so that the tool can be inserted between the selector 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 selector lever up and off. top of page

Installing selector knob

1. Assemble the selector knob with spring clip, compression spring and locking button. Note Fit conical compression spring with the small diameter facing the guide peg. 2. 37 04 19 Removing and installing selector knob 1240

einordnung Press the complete selector knob onto 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

Installing selector knob

1241

37 30 19 Removing and installing Tiptronic control module

Note Removing the control module Installing the control module Coding the Tiptronic control module Tightening torques Tools

Note

The control module is located in the passenger compartment on the right on the Bpillar in front of the rear seat well. The ignition key must be removed 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 control module

Remove front seat. 7, 720119 Removing and installing front seat Remove the side lining at rear right 707519 . Remove right sill 680519 1. Unscrew lower fastening screw for the seat belt. 2. Disengage floor covering at the support and lay it in the vehicle interior.

37 30 19 Removing and installing Tiptronic control module

1242

einordnung 3. Unlock locating peg 1 of the support using the commercially available removal tool. => Tightening torques

4. Unscrew fastening screws 2 and nuts 3 and carefully 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 at an angle.

8. Press locking tabs arrow and disconnect plug connections from the control module. top of page

Removing the control module

1243

einordnung

Installing the control module

1. Plug 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.

Installing the control module

1244

einordnung

5. Push in the locating peg 1 of the support and check that it is sitting correctly. 6. Tighten the fastening nuts 3 and the fastening screws 2 . Tightening torque 2 7.2 Nm (5.5ftlbs.). 7. Lay the floor covering over the support and engage. Using the Porsche System Tester, read out any 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 installing side panel lining Installing front seat. 7, 720119 Removing and installing front seat

top of page

Coding the Tiptronic control module

Note The adaptation values must be reset using the Porsche System Tester when the transmission is renewed/replaced. 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 minutes at idle speed. This ensures that all adaptation values are stored in the control module. The instructions of the Porsche System Tester have highest priority. The procedure listed has been structured generally, changes or additions can be made. The basis of this is the Tester Software 13.1. 1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch ignition on. 2. Select vehicle type using the cursor keys. 3. Using the >> key, move from the vehicle type to the list of control modules. 4. Select Tiptronic with the cursor keys and press the >> key. 5. Select "Coding" with the cursor keys and press the >> key. 6. Select vehicle version and code with the F8 key. Coding the Tiptronic control module 1245

einordnung RoW/ Japan Taiwan/ Korea P 80 P 83 / P 84

7. Tester confirmed: Coding has been modified . 8. Perform test drive and check fault memory with the System Tester. Resetting adaptation values: Proceed as described under point 1 4. Select menu item 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 Seat belt on body Fastening screw 2 Support

Thread

Tightening torque Nm (ftlb.) 50 7,2

top of page

Tools

Item

Special tool designation Removal tool

Remarks Commercially available HandbuchWerkstattausrstung Kapitel 2.4, Nr. 21 1246

Tightening torques

einordnung

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tools

1247

39 02 19 Removing and installing cardan shaft

Tools Removing cardan shaft Installing cardan shaft Tightening torques top of page

Tools

Item

Designation of the special tool Assembly sleeve 9255

Explanation

top of page

Removing cardan shaft

Note Observe max. joint angle of 20 when removing and fitting. Furthermore, the cardan joint must not be loaded at max. deflection (stop). 1. Remove underbody covers (rear and centre).

39 02 19 Removing and installing cardan shaft

1248

einordnung

2. Remove transmission support.

3. Detach cardan shaft at the transmission side and press it off the transmission flange with two mounting levers. 4. Pull cardan shaft out of the splines 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 for cardan shaft.

2. Slide special tool 9255 A over the shaft splines, lightly lubricate sleeve with Vaseline and push on the bellows to the stop. Removing cardan shaft 1249

einordnung

3. Grease bushing A with approx. 3 g of Olista Longtime 3EP . 4. Grease splines of the cardan shaft with Olista Longtime 3 EP . Slide shaft into the central shaft splines and fit on the transmission side.

5. Push bellows A forward until 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 Drive shaft on transmission flange Transmission support to transmission bearing Transmission support to body

Thread M10 M10 M10

Tightening torque Nm (ftlb.) 45 (33) 65 (48) 65 (48)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing cardan shaft

1250

39 02 19 Removing and installing cardan shaft

Tools Removing and installing cardan shaft Tightening torques top of page

Tools

Item

Designation of the special tool Assembly sleeve 9255

Explanation

top of page

Removing and installing cardan shaft

Removing cardan shaft

Note Observe max. joint angle of 20 when removing and fitting. Furthermore, the cardan joint must not be loaded at max. deflection (stop). 1. Remove underbody covers (rear and centre).

39 02 19 Removing and installing cardan shaft

1251

einordnung

2. Remove transmission support.

3. Detach cardan shaft at the transmission side and press it off the transmission flange with two mounting levers. 4. Pull cardan shaft out of the 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 cardan shaft.

2. Slide special tool 9255 A over the shaft splines, lightly lubricate sleeve with Vaseline and push on the bellows to the stop. Removing cardan shaft 1252

einordnung

3. Grease bushing A with approx. 3 g of Olista Longtime 3EP . 4. Grease splines of the cardan shaft with Olista Longtime 3 EP . Slide shaft into the central shaft splines and fit on the transmission side.

5. Push bellows A forward until 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 Drive shaft on transmission flange Transmission support to transmission bearing Transmission support to body

Thread M10 M10 M10

Tightening torque Nm (ftlb.) 45 (33) 65 (48) 65 (48)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing cardan shaft

1253

39 22 19 Removing and installing sealing ring for halfshaft flange

Tools Removing sealing ring for halfshaft flange Installing sealing ring for halfshaft flange Tightening torques top of page

Tools

Item 1

Designation of the special tool Pressure piece

Remarks Special tool pressure piece 9252

top of page

Removing sealing ring for halfshaft flange

Note Protect drive shafts from damage. (Use 30 mm piece of hose) 1. Uncouple drive shaft on the transmission side.

39 22 19 Removing and installing sealing ring for halfshaft flange

1254

einordnung

2. Unscrew fastening screw for the halfshaft flange, unclip the B+ cable on the air flange and pull out the halfshaft flange. 3. Lever out sealing ring using a suitable tool. top of page

Installing sealing ring for halfshaft flange

1. Fill the space between the dust and sealing lips with grease (e.g. LiquiMoly) and drive in the sealing ring up 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 mount the drive shaft. Tightening torque: 81 Nm (60 ftlbs.) top of page

Tightening torques

Location Halfshaft flange fastening screw Halfshaft flange on drive shaft

Thread M10 M10

Tightening torque Nm (ftlb.) 44 (32 ftlbs.) 81 (60 ftlbs.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Removing sealing ring for halfshaft flange

1255

39 22 19 Removing and installing sealing ring for short flanged shaft

Tools Removing and installing sealing ring for short flanged shaft Tightening torques top of page

Tools

Item A B C

Designation of the special tool Striker VW 771/1 Extraction tool VW 771/37 Pressure piece 9252

Explanation

top of page

Removing and installing sealing ring for short flanged shaft

Removing sealing ring for short flanged shaft

Note The short flanged shaft can be removed only by partially undoing the wheel suspension.

39 22 19 Removing and installing sealing ring for short flanged shaft

1256

einordnung 1. Remove right rear wheel. 2. Uncouple drive shaft on the transmission side.

3. Undo right stabilizer mount. Counter with an openended wrench when removing from the stabilizer fastening.

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 pull out flanged shaft.

7. Remove sealing ring with special tools VW 771/1 and VW 771/37 (Figure shows removed transmission).

Removing sealing ring for short flanged shaft

1257

einordnung

Installing sealing ring for short flanged shaft

Install in reverse order, observing the following points: Note The sealing ring must fit in the housing at the same depth all round.

1. Thinly coat sealing lip and outer circumference of sealing ring with Vaseline and insert sealing ring with special tool 9252 up to the stop (Figure shows removed transmission). 2. Fit drive 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 Wheel to wheel hub Drive shaft to transmission Stabilizer to carrier side section Stabilizer to stabilizer mount Control arm to carrier side section Short flanged shaft to transmission

Thread M14 x 1.5 M10 M8 M10 M12 x 1.5 M10

Tightening torque Nm (ftlb.) 130 (96) 81 (60) 23 (17) 46 (34) 110 (81) 46 (34)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing sealing ring for short flanged shaft

1258

39 25 19 Removing and installing long flanged shaft

Tools Removing and installing long flanged shaft Tightening torques top of page

Tools

Item

Designation of the special tool Torx socket wrench 9330

Explanation

top of page

Removing and installing long flanged shaft

Removing long flanged shaft

1. Remove left rear wheel. 2. Remove left drive shaft (refer to Serv. No. 422119). 3. Unscrew fastening screw for the water hose holder on the mounting saddle.

39 25 19 Removing and installing long flanged shaft

1259

einordnung

4. Unscrew fastening screws for the mounting saddle with a Torx socket wrench 9330 . 5. Carefully pull out flanged shaft.

Installing long flanged shaft

Install in reverse order, observing the following points:

1. Check flanged shaft for burrs and sharp edges on the transmission end of the shaft arrow and deburr if necessary. Note While being inserted, 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 water hoses and check for perfect seating of the hoses. top of page

Tightening torques

Location Mounting saddle for flanged shaft to transmission Drive shaft on flanged shaft Wheel to wheel hub Holder to mounting saddle

Thread M6 M10 M14 x 1.5 M6

Tightening torque Nm (ftlb.) 23 (17) 81 (60) 130 (96) 10 (7.5)

Removing long flanged shaft

1260

einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

1261

39 58 19 Removing and installing lid for front wheel drive

Tools Removing the lid for front wheel drive Installing the lid for front wheel drive Tightening torques top of page

Tools

Item

Designation of the special tool Centering pins 9321

Explanation 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 flanged shaft with two mounting levers. 4. Unscrew fastening screws for the lid and remove the lid by tapping it with a plastic hammer. top of page

39 58 19 Removing and installing lid for front wheel drive

1262

einordnung

Installing the lid for front wheel drive

Install in reverse order, observing the following points: 1. Fit sealing ring without twisting and coat it with Vaseline.

2. Fit lid carefully and tighten screws uniformly in diagonally opposite sequence. Use centering pins 9321 as an assembly aid. Tightening torque: 25 Nm (18 ftlb.) A Centering pins 9321

3. Always replace the snap ring for the halfshaft flange. To do 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 special tools pullin tool and extractor P 254 and pressure pieces (4 items) 9247 . 5. Fill in ATF => Changing transmission oil in front wheel drive. top of page

Tightening torques

Location Oil drain plug on final drive Cover on final drive

Thread M18 x 1.5 M8

Tightening torque Nm (ftlb.) 28 (21) 25 (18)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing the lid for front wheel drive

1263

39 58 19 Removing and installing lid for front wheel drive

Tools Removing the lid for front wheel drive Installing the lid for front wheel drive Tightening torques top of page

Tools

Item

Designation of the special tool Centering pins 9321

Explanation 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 flanged shaft with two mounting levers. 4. Unscrew fastening screws for the lid and remove the lid by tapping it with a plastic hammer. top of page

39 58 19 Removing and installing lid for front wheel drive

1264

einordnung

Installing the lid for front wheel drive

Install in reverse order, observing the following points: 1. Fit sealing ring without twisting and coat it with Vaseline. 2. Fit lid carefully and tighten screws uniformly in diagonally opposite sequence. Use centering pins 9321 as an assembly aid.

Tightening torque: 25 Nm (18 ftlb.) A Centering pins 9321

3. Always replace the snap ring for the halfshaft flange. To do 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 special tools pullin tool and extractor P 254 and pressure pieces (4 items) 9247 . 5. Fill in oil => Changing transmission oil in front wheel drive. top of page

Tightening torques

Location Oil drain plug on final drive Cover on final drive

Thread M18 x 1.5 M8

Tightening torque Nm (ftlb.) 28 (21) 25 (18)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing the lid for front wheel drive

1265

39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive)
Tools Removing the sealing ring for the flanged shaft (front wheel drive) Installing the sealing ring for the flanged shaft (front wheel drive) top of page

Tools

Item

Special tool designation Pressure piece 9537

Remarks

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 front drive shaft 2. Press out flanged shaft with two mounting levers. 3. Lever out sealing ring using a suitable tool. Note Do not damage the sealing ring seat!

39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive)

1266

einordnung

top of page

Installing the sealing ring for the flanged shaft (front wheel drive)

1. Fill the space between the dust and sealing lips arrow on the new sealing ring with grease (e.g. LiquiMoly).

2. Drive in the sealing ring with the special tool pressure 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 the vice with protective jaws and press out the old snap ring with the new snap ring A A New snap ring Note Do not damage the drive shaft teeth when replacing them.

Removing the sealing ring for the flanged shaft (front wheeldrive)

1267

einordnung

4. Grease the snap ring thoroughly and drive in the halfshaft flange arrow . 5. Check 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

Installing the sealing ring for the flanged shaft (front wheeldrive)

1268

39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive)
Tools Removing the sealing ring for the flanged shaft (front wheel drive) Installing the sealing ring for the flanged shaft (front wheel drive) top of page

Tools

Item

Special tool designation Pressure piece 9537

Remarks

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 front drive shaft 2. Press out flanged shaft with two mounting levers. 3. Lever out sealing ring using a suitable tool. Note Do not damage the sealing ring seat!

39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive)

1269

einordnung

top of page

Installing the sealing ring for the flanged shaft (front wheel drive)

1. Fill the space between the dust and sealing lips arrow on the new sealing ring with grease (e.g. LiquiMoly).

2. Drive in the sealing ring with the special tool pressure 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 the vice with protective jaws and press out the old snap ring with the new snap ring A A New snap ring Note Do not damage the drive shaft teeth when replacing them.

Removing the sealing ring for the flanged shaft (front wheeldrive)

1270

einordnung

4. Grease the snap ring thoroughly and drive in the halfshaft flange arrow . 5. Check 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

Installing the sealing ring for the flanged shaft (front wheeldrive)

1271

39 60 01 Checking function of installed viscous clutch

Test conditions Checking function of installed viscous clutch top of page

Test conditions
Test only with viscous clutch at room temperature. Test speed of front wheels between 3 km/h and 5 km/h (wheels driven by rollers of roller brake tester). Test duration 3 minutes; record the traction every 30 seconds. Repeat measurement after viscous clutch has cooled down for one hour.

top of page

Checking function of installed viscous clutch

1. Connect Porsche System Tester 2 and select Actual values menu (PSM speed). 2. Drive front wheels of the vehicle onto the roller brake tester. 3. Switch the engine off, set the hand brake and shift the transmission to neutral. 4. When the braketester rollers have started, switch the ignition on and press the Continue key of the Porsche System Tester 2. The Tester then returns to the point at which diagnosis was interrupted. 5. Drive front wheels by means of the brake tester rollers at a speed of 3 km/h, 4 km/h or 5 km/h. 6. Measure traction 6 times in three minutes. Measure the first traction value after 30 seconds operating time, then carry out five more measurements every 30 seconds. 7. The viscous clutch functions properly if the traction of the front wheels lies within the limit curves in the diagram, depending on the drive speed of the roller brake tester rollers. Diagram for roller brake tester speed 5 km/h:

39 60 01 Checking function of installed viscous clutch

1272

einordnung

A Relative measuring time in minutes B Traction at the front 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:

Checking function of installed viscous clutch

1273

einordnung

A Relative measuring time in minutes B Traction at the front wheels in Newtons (N)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Checking function of installed viscous clutch

1274

39 60 01 Checking function of installed viscous clutch

Test conditions Checking function of installed viscous clutch top of page

Test conditions
Test only with viscous clutch at room temperature. Test speed of front wheels between 3 km/h and 5 km/h (wheels driven by rollers of roller brake tester). Test duration 3 minutes; record the traction every 30 seconds. Repeat measurement after viscous clutch has cooled down for one hour.

top of page

Checking function of installed viscous clutch

1. Connect Porsche System Tester 2 and select Actual values menu (PSM speed). 2. Drive front wheels of the vehicle onto the roller brake tester. 3. Switch the engine off, set the hand brake and shift the transmission to neutral. 4. When the braketester rollers have started, switch the ignition on and press the Continue key of the Porsche System Tester 2. The Tester then returns to the point at which diagnosis was interrupted. 5. Drive front wheels by means of the brake tester rollers at a speed of 3 km/h, 4 km/h or 5 km/h. 6. Measure traction 6 times in three minutes. Measure the first traction value after 30 seconds operating time, then carry out five more measurements every 30 seconds. 7. The viscous clutch functions properly if the traction of the front wheels lies within the limit curves in the diagram, depending on the drive speed of the roller brake tester rollers. Diagram for roller brake tester speed 5 km/h:

39 60 01 Checking function of installed viscous clutch

1275

einordnung

A Relative measuring time in minutes B Traction at the front 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:

Checking function of installed viscous clutch

1276

einordnung

A Relative measuring time in minutes B Traction at the front wheels in Newtons (N)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Checking function of installed viscous clutch

1277

39 60 19 Removing and installing the viscous clutch

Tools Removing the viscous clutch Installing the viscous clutch Tightening torques top of page

Tools

Item A B

Designation of the special tool Assembly aid 9638 Holding rails VW 457

Explanation 2 parts Drill two 10.5 mm holes

39 60 19 Removing and installing the viscous clutch

1278

einordnung

1 Snap ring 2 Supporting ring 3 Viscous clutch top of page

Removing the viscous clutch

1. Remove the cardan shaft => Removing and installing cardan shaft. 2. Remove the final drive, front => 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 longneck pipe. A Special tool holding rails VW 457 4. Remove snap ring and take out viscous clutch with supporting ring. top of page

Installing the viscous clutch

Install in reverse order, observing the following points:

Tools

1279

einordnung

1. Insert supporting ring and fit snap ring B with special tool A assembly aid 9638 . A Special tool assembly aid 9638 B Snap ring 2. Always replace Oring for longneck pipe and coat with Vaseline. 3. Uniformly tighten fastening screws for longneck pipe in diagonally opposite sequence. 4. Fill in oil for final drive => Changing transmission oil in front wheel drive. top of page

Tightening torques

Location Longneck pipe on final drive Front transmission support on final drive Oil drain plug on final drive

Thread M8 x 36 M10 M18 x 1.5

Tightening torque Nm (ftlb.) 25 Nm (18 ftlb.) 65 Nm (48 ftlb.) 28 Nm (21 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing the viscous clutch

1280

39 60 19 Removing and installing the viscous clutch

Tools Removing the viscous clutch Installing the viscous clutch Tightening torques top of page

Tools

Item A B

Designation of the special tool Assembly aid 9638 Holding rails VW 457

Explanation 2 parts Drill two 10.5 mm holes

39 60 19 Removing and installing the viscous clutch

1281

einordnung

1 Snap ring 2 Supporting ring 3 Viscous clutch top of page

Removing the viscous clutch

1. Remove the cardan shaft => Removing and installing cardan shaft. 2. Remove the final drive, front => 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 longneck pipe. A Special tool holding rails VW 457 4. Remove snap ring and take out viscous clutch with supporting ring. top of page

Installing the viscous clutch

Install in reverse order, observing the following points:

Tools

1282

einordnung

1. Insert supporting ring and fit snap ring with special tool assembly aid 9638 . A Special tool assembly aid 9638 B Snap ring 2. Always replace Oring for longneck pipe and coat with Vaseline. 3. Uniformly tighten fastening screws for longneck pipe in diagonally opposite sequence. 4. Fill in oil for final drive => Replacing and checking transmission oil in final drive . top of page

Tightening torques

Location Longneck pipe on final drive Front transmission support on final drive Oil drain plug on final drive

Thread M8 x 36 M10 M18 x 1.5

Tightening torque Nm (ftlb.) 25 Nm (18 ftlb.) 65 Nm (48 ftlb.) 28 Nm (21 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing the viscous clutch

1283

39 62 19 Removing and installing support for front wheel drive

Removing the support for front wheel drive Installing the support for front wheel drive Tightening torques

A Support for final 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. top of page

Installing the support for front wheel drive

1. Mount support in correct position (angled side faces upwards)

39 62 19 Removing and installing support for front wheel drive

1284

einordnung 2. Tighten the fastening screws in two stages 1. Pretighten both screws to 5 Nm (3.5 ftlb.). 2. Tighten both screws to 65 Nm (48 ftlb.). 3. Install the final drive => Removing and installing front wheel drive. top of page

Tightening torques

Location Transmission support on final drive

Thread M10

Tightening torque Nm (ftlb.) 65 (48)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing the support for front wheel drive

1285

39 62 19 Removing and installing support for front wheel drive

Removing the support for front wheel drive Installing the support for front wheel drive Tightening torques

A Support for final 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. top of page

Installing the support for front wheel drive

1. Mount support in correct position (angled side faces upwards).

39 62 19 Removing and installing support for front wheel drive

1286

einordnung 2. Tighten the fastening screws in two stages. 1. Pretighten both screws to 5 Nm (3.5 ftlb.). 2. Tighten both screws to 65 Nm (48 ftlb.). 3. Install the final drive => Removing and installing front wheel drive. top of page

Tightening torques

Location Transmission support on final drive

Thread M10

Tightening torque Nm (ftlb.) 65 (48)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing the support for front wheel drive

1287

39 82 19 Removing and installing sealing ring for cardan flange

Tools Removing sealing ring for cardan flange Installing sealing ring for cardan flange Tightening torques top of page

Tools

Item A B C D

Designation of the special tool Explanation Socket wrench insert commercially available (refer to Workshop Equipment Manual, Chapter 2.4, No. 64) Pressure piece 9671 Threearm puller Commercially available (refer to Technical Equipment Manual, Chapter 2.4, No. 1121) Hook VW 681

top of page

Removing sealing ring for cardan flange

1. Remove the cardan shaft => Removing and installing cardan shaft. 2. Place oil collection tray under the transmission.

39 82 19 Removing and installing sealing ring for cardan flange

1288

einordnung 3. Engage a gear and firmly set the hand brake.

4. Remove collar nut with a long a/f 30 socket wrench insert (refer to Workshop Equipment Manual, Chapter 2.4, No. 64).

5. Pull off the cardan flange with a threearm puller (refer to Workshop Equipment Manual, Chapter 2.4, No. 1121). 6. Lever out the sealing ring on alternate sides with special tool hook VW 681 . top of page

Installing sealing ring for cardan flange

1. 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 lips on the sealing ring with grease (e.g. Liqui Moly) and drive in the sealing ring up to the mounting face using special tool pressure piece 9671 . 3. Coat halfshaft flange splines with screw locking lacquer (e.g. Loctite 243 or Omnifit 50 M) and fit the flange. 4. Coat contact surface and thread of the collar nut with screw locking lacquer (as in step 4).

Removing sealing ring for cardan flange

1289

einordnung

5. Tighten the collar nut. Tightening torque: 120 Nm (89 ftlb.) 1 Halfshaft flange 2 Collar nut A Screw locking lacquer (Loctite 243 or Omnifit 50 M) 6. Check transmission oil => Changing transmission oil. top of page

Tightening torques

Location Collar nut/halfshaft flange

Thread M20 x 1.5

Tightening torque Nm (ftlb.) 120 (89)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing sealing ring for cardan flange

1290

39 82 19 Removing and installing sealing ring for cardan flange

Tools Removing and installing sealing ring for cardan flange Tightening torques top of page

Tools

Item A B C D

Designation of the special tool Explanation Socket wrench 9669 Pressure piece 9668 Threearm puller Commercially available (refer to Technical Equipment Manual, Chapter 2.4, No. 1121) Hook VW 681

top of page

Removing and installing sealing ring for cardan flange

Removing sealing ring for cardan flange

1. Remove cardan shaft (refer to Serv. No. 390219). 2. 39 82 19 Removing and installing sealing ring for cardan flange 1291

einordnung Place oil collection tray under the transmission. 3. Engage parking lock and firmly set the parking brake.

4. Remove collar nut with special tool 9669. 5. Pull off the cardan flange with a threearm puller (refer to Workshop Equipment Manual, Chapter 2.4, No. 1121).

6. Lever off sealing ring with special tool VW 681.

Installing sealing ring for cardan flange

1. Replace Oring for cardan flange.

2. Fill the space between the dust and sealing lips on the sealing ring with grease (e.g. Liqui Moly) and drive in the sealing ring up to the mounting face using special tool 9668.

Removing sealing ring for cardan flange

1292

einordnung

3. Tighten collar nut and secure by pressing in the collar. Tightening torque: 160 Nm (118 ftlb.) 4. Install cardan shaft (refer to Serv. No. 390219). top of page

Tightening torques

Location Collar nut

Thread 24 x 1.5

Tightening torque Nm (ftlb.) 160 (118)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing sealing ring for cardan flange

1293

39 88 19 Removing and installing front wheel drive

Remove front wheel drive Installing the front wheel drive Tightening torques

1 2 3 4 5

Final drive front Longneck pipe with central pipe Cardan shaft Transmission support, rear 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 brace A and cover B . 4. Remove drive shafts at the transmission and protect the shafts against damage (use scrap pieces of hose with a diameter of 30 mm). Note 39 88 19 Removing and installing front wheel drive 1294

einordnung To protect the coolant pipes against scratches when the final drive is removed or installed, it is advisable to protect the pipes with adhesive tape in the area of the final drive. 5. Place transmission jack under the transmission and secure with fixing strap.

6. Remove pipe holder and 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 the studs. A Transmission support B Hexagon nut C Stud 8. Carefully lower the transmission out. When doing so, avoid damaging the coolant pipes. top of page

Installing the front wheel drive

Install in reverse order, observing the following points:

Remove front wheel drive

1295

einordnung

1. Carefully lift in the transmission with a universal transmission jack. When doing so, do not damage the coolant pipes. 2. Push studs through the front transmission mounts and screw into the frontaxle cross member. Note If the hexagonhead bolt (M10 x 90) was undone on the rear transmission support/transmission mount, it is essential to tighten the front transmission support first, then the rear transmission support and the M10 x 90 screw on the rear transmission mount last. 3. Fasten transmission mounts on the frontaxle cross member and on the body. top of page

Tightening torques

Location Studs on frontaxle cross member Front transmission support on transmission Front transmission support on frontaxle cross member Rear transmission support to body Rear transmission support to transmission bearing Drive shafts on frontaxle final drive Diagonal brace on body and frontaxle cross member Tank strap on body Pipe holder on transmission support

Thread M8 M10 M10 M10 M10 x 90 M8 M12 M8 x 40 M6

Tightening torque Nm (ftlb.) 20 Nm (15 ftlb.) 65 Nm (48 ftlb.) 65 Nm (48 ftlb.) 65 Nm (48 ftlb.) 65 Nm (48 ftlb.) 39 Nm (29 ftlb.) 100 Nm (74 ftlb.) 23 Nm (17 ftlb.) 7 Nm (5 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing the front wheel drive

1296

39 88 19 Removing and installing front wheel drive

Removing front wheel drive Installing the front wheel drive Tightening torques

1 2 3 4 5

Final drive front Longneck pipe with central pipe Cardan shaft Transmission support, rear 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 diagonal brace A and cover B . 4. Remove drive shafts at the transmission and protect the shafts against damage (use scrap pieces of hose with a diameter of 30 mm). Note 39 88 19 Removing and installing front wheel drive 1297

einordnung To protect the coolant pipes against scratches when the final drive is removed or installed, it is advisable to protect the pipes with adhesive tape in the area of the final drive! 5. Place transmission jack under the transmission and secure with fixing strap.

6. Remove pipe holder and 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 the studs. A Transmission support B Hexagon nut C Stud 8. Carefully lower the transmission out. When doing so, avoid damaging the coolant pipes. top of page

Installing the front wheel drive

Install in reverse order, observing the following points:

Removing front wheel drive

1298

einordnung

1. Carefully lift in the transmission with a universal transmission jack. When doing so, do not damage the coolant pipes. 2. Push studs through the front transmission mounts and screw into the frontaxle cross member. Note If the hexagonhead bolt (M10 x 90) was undone on the rear transmission support/transmission mount, it is essential to tighten the front transmission support first, then the rear transmission support and the M10 x 90 screw on the rear transmission mount last! 3. Fasten transmission mounts on the frontaxle cross member and on the body. top of page

Tightening torques

Location Studs on frontaxle cross member Front transmission support on transmission Front transmission support on frontaxle cross member Rear transmission support on body Rear transmission support on transmission mount Drive shafts on frontaxle final drive Diagonal braces on body and frontaxle cross member Tank strap on body Pipe holder on transmission support

Thread M8 M10 M10 M10 M10 x 90 M8 M12 M8 x 40 M6

Tightening torque Nm (ftlb.) 20 Nm (15 ftlb.) 65 Nm (48 ftlb.) 65 Nm (48 ftlb.) 65 Nm (48 ftlb.) 65 Nm (48 ftlb.) 39 Nm (29 ftlb.) 100 Nm (74 ftlb.) 23 Nm (17 ftlb.) 7 Nm (5 ftlb.)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing the front wheel drive

1299

39 90 55 Replacing and checking transmission oil in final drive

Tools Changing transmission oil in final drive Tightening torques top of page

Tools

Item

Designation of the special tool Filling system V.A.G 1924

Explanation

top of page

Changing transmission oil in final drive

Note Use only oils approved by Porsche. See Parts Catalogue! Filling capacity: 1.2 litres

39 90 55 Replacing and checking transmission oil in final drive

1300

einordnung

1. Unscrew oil filler plug A .

2. Unscrew oil drain plug arrow . Drain oil with vehicle standing horizontally. 3. Clean the drain plug and filler plug. 4. Replace sealing rings for the drain plug and filler plug. Note Attach the special tool as high as possible 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 opening and use it to read the oil level. 7. Screw in and tighten the filler plug and drain plug. Filler plug tightening torque: 22 Nm (16 ftlb.) Drain plug tightening torque: 25 Nm (19 ftlb.) top of page

Changing transmission oil in final drive

1301

einordnung

Tightening torques

Location Oil drain plug Oil filler plug

Thread M21 x 1.5 M18 x 1.5

Tightening torque Nm (ftlb.) 25 (19) 22 (16)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

1302

39 90 55 Changing transmission oil in front wheel drive

Changing transmission oil in front wheel drive Tightening torques top of page

Changing transmission oil in front wheel drive

Note Use only oils approved by Porsche. See Parts Catalogue! 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 filler plug. 5. Fill with oil up to the bottom edge of the oil filler opening. 6. Tighten the drain plug and filler plug. Tightening torque: 28 Nm (21 ftlb.). top of page

Tightening torques

39 90 55 Changing transmission oil in front wheel drive

1303

einordnung Location Screw plug, oil drainage and oil filling Thread M18 Tightening torque Nm (ftlb.) 28 (21)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

1304

39 90 55 Changing transmission oil in front wheel drive

Changing transmission oil in front wheel drive Tightening torques top of page

Changing transmission oil in front wheel drive

Note Use only oils approved by Porsche. See Parts Catalogue! 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 filler plug. 5. Fill with oil up to the bottom edge of the oil filler opening. 6. Tighten the drain plug and filler plug. Tightening torque: 28 Nm (21 ftlb.). top of page

Tightening torques

39 90 55 Changing transmission oil in front wheel drive

1305

einordnung Location Screw plug, oil drainage and oil filling Thread M18 Tightening torque Nm (ftlb.) 28 (21)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

1306

42 21 19 Removing and installing rear drive shaft (manual transmission)

Tools Removing the drive shaft (manual transmission) Installing the drive shaft (manual transmission) top of page

Tools

Item Designation of the special tool A Torx screwdriver 9546 B C D

Explanation To counter the ball joints (track rod) during assembly and disassembly. Pressout tool (ball joint extractor) To press out the ball joint on the wheel carrier. 9560 Protective tube Protection of the drive shaft. Wheelhub extractor To press the drive shaft out of the wheel hub.

top of page

Removing the drive shaft (manual transmission)

42 21 19 Removing and installing rear drive shaft (manual transmission)

1307

einordnung

Note

Since the drive shaft can be moved only using great force, loosen the shaft inwards with taps on a copper mandrel! For unfavourable tolerances, the drive shaft must be pressed out of the toothing using a universal wheelhub extractor! See step 9 also. 1. Lift the vehicle. Remove the wheel and undo axle nut arrow . Actuate the foot brake and parking brake for this purpose. 2. Push the protection arrow over the drive shaft. Removing the drive shaft (manual transmission) 1308

einordnung 3. Undo the drive shaft on the transmission flange. 4. Unscrew the lower linkage for the headlight height adjustment arrow (counter with openended wrench). Only on left side! 5. Loosen stabilizer mount arrow at stabilizer (counter with openended wrench).

7. Remove the lower fastening screw of the spring 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 pressout tool 9560 . 9. Disengage the parking brake cable at the parking brake lever. To do this, remove the floor of the oddments tray in the centre console. Undo the 2 M8 nuts 1 . Remove the tab washer 3 from the retaining lug 4 with a screwdriver. Take the corresponding parking brake cable out of the guide. 10. Removing the drive shaft (manual transmission) 1309

einordnung Press the wear indicator/speed sensor wire out of the holder. Undo both upper axle struts and remove the screws. Press the drive shaft out, if necessary (given unfavourable tolerances) with a wheelhub 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 shaft (manual transmission)

CAUTION Danger of injury and material damage if the wheel carrier is raised incorrectly!

Installing the drive shaft (manual transmission)

1310

einordnung Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels)! When raising, use a suitable intermediate layer (hard rubber)! Do not damage the brake cover plate! Note Carry out a visual inspection of all parts! Grease the drive shaft toothing with Optimoly HT! Replace selflocking nuts!

The entire threaded parts of the axle must 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 not damage the brake cover plate! Use correct tightening torques! It is not 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 fitter is required! 2. Fit both axle struts arrows on the wheel carrier. Insert wear indicator/speed sensor wire in the holder. 3. Engage the inside parking brake cable (reverse procedure to that described in Point 8 Removal). Note When inserting the parking brake cable into the guide tube of the body, always make sure that the sleeve of the parking brake cable is pushed fully onto the guide tube. Otherwise, correct adjustment of the parking brake will not be possible. 4. Mount the tie rod end on the wheel carrier. 5. Insert the fastening screw of the lower spring strut arrow .

Installing the drive shaft (manual transmission)

1311

einordnung

7. Screw on the stabilizer mount arrow . Counter with an openended wrench when doing this. 8. Screw on the lower linkage for the headlight height adjustment arrow (counter with openended 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 wheel.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing the drive shaft (manual transmission)

1312

42 21 19 Removing and installing rear drive shaft (Tiptronic transmission)

Tools Removing the drive shaft (Tiptronic transmission) Installing the drive shaft (Tiptronic transmission) top of page

Tools

Item Designation of the special tool A Torx screwdriver 9546 B C D

Explanation To counter the ball joints (track rod) during assembly and disassembly. Pressout tool (ball joint extractor) To press out the ball joint on the wheel carrier. 9560 Protective tube Protection of the drive shaft. Wheelhub extractor To press the drive shaft out of the wheel hub.

top of page

Removing the drive shaft (Tiptronic transmission)

42 21 19 Removing and installing rear drive shaft (Tiptronic transmission)

1313

einordnung

Note

Since the drive shaft can be moved only using great force, loosen the shaft inwards with taps on a copper mandrel! For unfavourable tolerances, the drive shaft must be pressed out of the toothing using a universal wheelhub extractor! See step 9 also. 1. Lift the vehicle. Remove the wheel and undo axle nut arrow . Actuate the foot brake and parking brake for this purpose. 2. Push the protection arrow over the drive shaft. Removing the drive shaft (Tiptronic transmission) 1314

einordnung 3. Undo the drive shaft with spacer ring on the transmission flange. 4. Unscrew the lower linkage for the headlight height adjustment arrow (left side only). Counter with openended wrench. 5. Loosen stabilizer mount arrow at stabilizer (counter with openended wrench).

7. Remove the lower fastening screw of the spring 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 pressout tool 9560 . 9. Disengage the parking brake cable at the parking brake lever. To do this, remove the floor of the oddments tray in the centre console. Undo the 2 M8 nuts 1 . Remove the tab washer 3 from the retaining lug 4 with a screwdriver. Take the corresponding parking brake cable out of the guide. 10. Removing the drive shaft (Tiptronic transmission) 1315

einordnung Press the wear indicator/speed sensor wire out of the holder. Undo both upper axle struts and remove the screws. Remove spacer ring from inner joint. Press the drive shaft out, if necessary (given unfavourable tolerances) with a wheelhub 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 shaft (Tiptronic transmission)

CAUTION Danger of injury and material damage if the wheel carrier is raised incorrectly!

Installing the drive shaft (Tiptronic transmission)

1316

einordnung Do not raise the wheel suspension higher than the normal vehicle position (vehicle resting on wheels)! When raising, use a suitable intermediate layer (hard rubber)! Do not damage the brake cover plate! Note Carry out a visual inspection of all parts! Grease the drive shaft toothing with Optimoly HT! Replace selflocking nuts!

A spacer ring is fitted between the drive shaft and transmission arrow ! The spacer ring is installed in Tiptronic vehicles only!

The entire threaded parts of the axle must 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 not damage the brake cover plate! Use correct tightening torques! It is not 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 retracted. A second fitter is required! 2. Push spacer ring onto inner joint. Fit both axle struts arrows on the wheel carrier. Insert wear indicator/speed sensor wire in the Installing the drive shaft (Tiptronic transmission) 1317

einordnung holder. 3. Push sleeve arrow of the parking brake cable B over the parking brake cable guide tube A (push it onto the guide tube as far as the stop). Engage the inside parking brake (reverse procedure to that described 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 parking brake will not be possible. 4. Mount the tie rod end on the wheel carrier. 5. Insert the fastening screw of the lower spring strut arrow .

Installing the drive shaft (Tiptronic transmission)

1318

einordnung

7. Screw on the stabilizer mount arrow . Counter with an openended wrench when doing this. 8. Screw on the lower linkage for the headlight height adjustment arrow (counter with openended 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 nut. Fasten the wheel.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing the drive shaft (Tiptronic transmission)

1319

45 46 19 Removing and installing front ABS lead

Removing front ABS lead Installing front ABS lead Tightening torques Tools

top of page

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 panel cover at centre and left. 6, 664419 Removing and installing cowl panel cover

45 46 19 Removing and installing front ABS lead

1320

einordnung

1. Release lead lock for ABS lead plug arrow A and pull off both plugs arrow B . 2. Unscrew the fastening nut 1 .

3. Take the 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 is sufficient for attaching the new lead. 6. Cut the lead in area D and remove it.

Removing front ABS lead

1321

einordnung

7. Cut through the fabric tape in the radiator tank, in the area a , and expose the remaining ABS lead. top of page

Installing front ABS 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 engage on the plugs.

4. Press the lead into the holders by pressing on the rubber sleeves arrow .

Installing front ABS lead

1322

einordnung

5. Secure lead for headlight beam adjustment to the ABS lead using fabric tape A . 6. Position the lead in installation position and close the clips arrows B . 7. Push the lead through to the interior arrow C .

Note

Do not cut the ends of the lead too short so that the connection area can be moved from the original installation position, if necessary, if there is insufficient space available. The individual leads in the wiring harness must be crimped and offset with respect to each other so that the repair area does not become too thick. 8. Cut the ends of the lead to the required length and crimp it in area a with a crimp connector and crimping tool. => Tools Cut off leads to different lengths (due to the shrink connection). Slide shrinkfit hose over the leads. Strip 10 mm of insulation off the leads. Connect leads with crimp connectors (do not confuse colours of the individual leads). Shrink shrinkfit hoses with a hotair 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 tiewraps b . Install cowl panel cover at centre and left. 6, 664419 Removing and installing cowl panel cover Install front wheel housing liner. 6, 505619 Removing and installing front wheel housing liner Fit front wheel. => Removing and installing the wheel Turbo and GT2

top of page Installing front ABS lead 1323

einordnung

Tightening torques

Location Fastening nut 1 for securing ABS lead to spring strut

Thread M6

Tightening torque [Nm] (ftlb.) 9.7 (7.2)

top of page

Tools

Item 1

Designation of special tool Repair set for wiring harness 1551

Remarks Workshop Equipment Manual, Gr. 2.4

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tightening torques

1324

45 46 19 Removing and installing rear 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 installing rear ABS lead (Turbo & GT2) 1325

einordnung installing the wheel Turbo and GT2 All models except for GT2 and GT3 Remove rear backrest. 7, 724719 Removing and installing rear backrest Remove emergency seat cushion. 7, 745719 Removing and installing emergency seat cushion Release rear threepoint belt. 6, 691219 Removing and installing rear threepoint belt Remove sidepanel lining. 7, 707519 Removing and installing sidepanel lining

1. Pull up carpet lining arrow A . 2. Fold carpeted floor forwards arrow B .

3. Release lead lock arrow A and pull off both plugs arrow B . 4. Unscrew fastening nut 1 and remove the plug arrow C .

Removing rear ABS lead

1326

einordnung

5. Take the lead out of the holders arrows .

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 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 at the side of the HBA lead a and remove the HBA lead arrow . top of page

Installing rear ABS lead

Installing rear ABS lead

1327

einordnung

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 engage on the plugs.

4. Press 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 in the wiring harness must be crimped and offset with respect to each other so that the repair area does not become too thick.

5. Push the lead through to the interior arrow . Installing rear ABS lead 1328

einordnung

Note

Only for vehicles with headlight beam adjustment (HBA) 6. Cut through the rubber sleeve a and position the HBA lead in the rubber sleeve arrow A . 7. Stick the rubber sleeve together and seal it at the cut edge a using a commercially available PUR adhesive. Then press the rubber sleeve into the opening arrow B .

8. Crimp the lead in area b using a crimp connector and crimping tool. => Tools Cut off leads to different lengths (due to the shrink connection). Slide shrinkfit hose over the leads. Strip 10 mm of insulation off the leads. Connect leads with crimp connectors (do not confuse colours of the individual leads). Shrink shrinkfit hoses with a hotair gun. It is essential that all leads are watertight. Wrap commercially available PVC tape all around the area of the connection points. All models Install rear wheel. => Removing and installing the wheel Turbo and GT2 All models except for GT2 and GT3 Install rear backrest. 7, 724719 Removing and installing rear backrest Install emergency seat cushion. 7, 745719 Removing and installing emergency seat cushion Secure rear threepoint belt. 6, 691219 Removing and installing 1329

Installing rear ABS lead

einordnung rear threepoint belt Install sidepanel lining. 7, 707519 Removing and installing sidepanel lining

top of page

Tightening torques

Location Fastening nut 1 for securing ABS lead to spring strut

Thread M6

Tightening torque [Nm] (ftlb.) 9.7 (7.2)

top of page

Tools

Item 1

Designation of special tool Repair set for wiring harness 1551

Remarks Workshop Equipment Manual, Gr. 2.4

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Tightening torques

1330

46 50 02 Checking front gray cast iron brake discs (wear assessment)

General 1. Visual inspection for cracks and evaluating cracks 2. Checking brake discs for minimum thickness Notes on bedding in the new brake pads Includes: 1. Visual inspection for cracks and evaluating cracks => 1. Visual inspection for cracks and evaluating cracks 2. Checking brake discs for minimum thickness. => 2. Checking brake discs for minimum thickness top of page

General
The condition of the parts can make replacement necessary under two criteria, depending on the wear of perforated brake discs: 1. Cracking in the holed (perforated) friction plate is in an advanced state. 2. Brake disc minimum thickness is not attained due to wear (material erosion due to friction). In practice, both forms of disc erosion occur. Usually, it is necessary to replace the brake discs when they fall short of the brake disc minimum thickness. Only in rare cases (for longterm race driving brake 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 acceptable disc condition will be described separately in the following sections. top of page

1. Visual inspection for cracks and evaluating cracks

Note Perforation starter cracks arise through material fatigue due to frequent and extreme heat elongation fluctuations. These fluctuations in the disc temperature, which generally arise in racing, tear the perforations in a radial direction due to material fatigue (changing heat elongation conditions). For their part, these starter cracks allow a partial relaxation of the friction plate, so that the speed at which the cracks develop is very slow. The maximum permissible perforation crack length is 5 mm. The growth of the perforation starter cracks or a tearing of the rim of the friction plate worsens the smoothness of braking, decreases the disc strength and therefore makes a precautionary parts replacement necessary.

46 50 02 Checking front gray cast iron brake discs (wear assessment)

1331

einordnung

Evaluating the cracks on the gray cast iron brake discs

The brake discs must be replaced (as a precautionary measure), if the perforation crack length is over 5 mm (as there is no mileage reserve in the event of further extreme load) or / and the friction plate rim is torn (lessens smoothness of braking and increases the liklihood that a disc will break)! In the evaluation of damage, the following drawings must be used!

A. Corresponds to a disc exposed to aboveaverage load. Need not be taken out of the vehicle!

B. In parts, perforation starter cracks over 7 mm long. Conditions after shock braking 1,200 times (minimum desired: shock braking 200 times). Brake disc can no longer be used!

C. Brake disc with torn friction plate rim arrow . Brake disc can no longer be used!

Evaluating the cracks on the gray cast iron brake discs

1332

einordnung top of page

2. Checking brake discs for minimum thickness

Note

In the presence of high pressure forces, at the innermost and outermost holefree friction plate track arrows , the brake lining friction surface is the least worn, compared to the middle holed area. As a result, in the case of weaker braking, a relatively higher surface pressure arises in these areas and therefore greater wear of the friction plates. The natural balance between stronger and weaker braking ensures that in almost all cases the typical wear profile of a perforated friction plate arises (inner and outer smooth friction rim area is worn the mostarrows . As opposed to smooth brake discs, by which the 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 track arrows , whichever is most worn. Brake disc thickness/wear limit: Max. 2.0 mm total wear permissible. Refer to the technical data for the new dimension and other dimensions 46 Technical data/wear limits Turbo or GT2 with gray cast iron brake discs .

Measure the smallest brake disc thickness with a suitable micrometer screw, at one of the two smooth friction rim areas arrows (at the most worn friction rim area).

The following drawing shows the typical grooved wear profile arrows of a perforated gray cast iron brake disc, which has been used to the wear limit, under tough conditions i.e. constant operation mode (test 2. Checking brake discs for minimum thickness 1333

einordnung operation mode). Arrows Zone where most wear occurs in brake disc friction surface A Perforation friction zone (holed friction zone) B smooth friction rim zone top of page

Notes on bedding in the new brake pads

In the case of the perforated (holed) friction plate, the contact pattern of newly installed brake pads adapts more quickly to the wear 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 (beddingin period), their optimum braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking effect must be compensated for by increased pressure on the brake pedal. The same also applies after a brake disc change.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Notes on bedding in the new brake pads

1334

46 50 02 Checking front PCCB brake discs (wear assessment)

General 1. Visual inspection of the surfaces of the brake disc friction surfaces 2. Checking brake discs for minimum thickness 3. Checking brake discs for edge damage Note concerning bores (perforations) in the brake disc friction surface Note on bedding in the new brake pads Includes: 1. Visual inspection for surface changes in the brake disc friction surfaces (wear assessment). 2. Check brake disc for minimum thickness (wear assessment/max. permissable total wear 0.5 mm) => 2. Checking brake discs for minimum thickness. 3. Check brake discs for edge damage (damage due to improper use) => 3. Checking brake discs for edge damage . top of page

General
Two conditions of criteria can make replacement necessary depending on the wear of perforated brake discs: 1. Surface changes in the brake 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 cases (for longterm race driving brake loads / very high temperature fluctuations in the friction surfaces), the surface changes can proceed so quickly that a premature disc change has to be performed. top of page

1. Visual inspection of the surfaces of the brake disc friction surfaces

Note The friction surface changes occur due to material fatigue as a result of extremely high thermal load. These disc temperatures which occur above all in racing operation cause a progressive material fatigue. Effects on driving: The surface change worsens the smoothness of braking, decreases the disc strength and increases the brake pad wear and therefore makes a precautionary parts replacement necessary. The following illustrations (PCCB brake disc wear appearance) are to be used.

46 50 02 Checking front PCCB brake discs (wear assessment)

1335

einordnung

PCCB brake disc wear appearance

A. Friction area surface after normal brake load in street use operation. No replacement necessary!

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 brake discs in the case of connected friction surface damage > 1 cm2 .

top of page

PCCB brake disc wear appearance

1336

einordnung

2. Checking brake discs for minimum thickness

Note For perforated brake discs, the minimum thickness must always be measured on the inner or outer friction surface trace. Brake disc thickness/wear limit: Max. 0.5 mm total wear permissible. Refer to the technical data for the new dimension and other dimensions 46 Technical data/wear limits GT2 or Turbo with PCCB .

Measure the brake disc thickness dimension 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 wear, a brake disc change can be necessary on the brake disc friction surfaces due to edge damage! In this case, only one brake disc can be replaced if the friction area surface of the other PCCB brake disc is in order.

The following criteria applies to edge damage assessment: Max. permissible width/depth = 2 mm! Max. permissible length = 10 mm! 2. Checking brake discs for minimum thickness 1337

einordnung Max. 3 damaged edge areas permissible!

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Note concerning bores (perforations) in the brake disc friction surface

CAUTION PCCB (Porsche Ceramic Composite Brake): Danger of material damage (danger of damage to the brake discs) if improper work is performed on the bores in the brake disc friction surface! Clean the bores on PCCB brake discs with highpressure cleaning equipment (only if necessary). In doing so, observe the environmental and safety regulations! Do not machine (boring or countersinking is not permissible)!

Use highpressure 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 beddingin period for PCCB brake discs than cast iron brake discs. In general, the following applies: New brake pads must be broken in (beddingin period), their optimum braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking effect must be compensated for by increased pressure on the brake pedal. The same also applies after a brake disc change.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

3. Checking brake discs for edge damage

1338

46 53 02 Checking rear gray cast iron brake discs (wear assessment)

General 1. Visual inspection for cracks and evaluating cracks 2. Checking brake discs for minimum thickness Notes on bedding in the new brake pads Includes: 1. Visual inspection for cracks and evaluating cracks => 1. Visual inspection for cracks and evaluating cracks 2. Checking brake discs for minimum thickness. => 2. Checking brake discs for minimum thickness top of page

General
The condition of the parts can make replacement necessary under two criteria, depending on the wear of perforated brake discs: 1. Cracking in the holed (perforated) friction plate is in an advanced state. 2. Brake disc minimum thickness is not attained due to wear (material erosion due to friction). In practice, both forms of disc erosion occur. Usually, it is necessary to replace the brake discs when they fall short of the brake disc minimum thickness. Only in rare cases (for longterm race driving brake 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 acceptable disc condition will be described separately in the following sections. top of page

1. Visual inspection for cracks and evaluating cracks

Note Perforation starter cracks arise through material fatigue due to frequent and extreme heat elongation fluctuations. These fluctuations in the disc temperature, which generally arise in racing conditions, tear the perforations in a radial direction due to material fatigue (changing heat elongation conditions). For their part, these starter cracks allow a partial relaxation of the friction plate, so that the speed at which the cracks develop is very slow. The maximum permissible perforation crack length is 5 mm. The growth of the perforation starter cracks or a tearing of the rim of the friction plate worsens the smoothness of braking, decreases the disc strength and therefore makes a precautionary parts replacement necessary.

46 53 02 Checking rear gray cast iron brake discs (wear assessment)

1339

einordnung

Evaluating the cracks on the gray cast iron brake discs

The brake discs must be replaced (as a precautionary measure), if the perforation crack length is over 5 mm (as there is no mileage reserve in the event of further extreme load) or / and the friction plate rim is torn (less smooth braking and an increase in the liklihood that a disc will break)! In the evaluation of damage, the following drawings must be used!

A. Corresponds to a disc exposed to aboveaverage load. Need not be taken out of the vehicle!

B. In parts, perforation starter cracks over 7 mm long. Conditions after shock braking 1,200 times (minimum desired: shock braking 200 times). Brake disc can no longer be used!

C. Brake disc with torn friction plate rim arrow . Brake disc can no longer be used!

Evaluating the cracks on the gray cast iron brake discs

1340

einordnung top of page

2. Checking brake discs for minimum thickness

Note

In the presence of high pressure forces, at the innermost and outermost holefree friction plate track arrows , the brake pad friction surface is the least worn, compared to the middle holed area. As a result, in the case of weaker braking, a relatively higher surface pressure arises in these areas and therefore greater wear of the friction plates. The natural balance between stronger and weaker braking ensures that in almost all cases the typical wear profile of a perforated friction plate arises (inner and outer smooth friction rim area is the most worn) arrows . As opposed to smooth brake discs, by which the 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 track, arrows whichever is most worn. Brake disc thickness/wear limit: Max. 2.0 mm total wear permissible. Refer to the technical data for the new dimension and other dimensions 46 Technical data/wear limits Turbo or GT2 with gray cast iron brake discs .

Measure the brake disc thinnest point with a suitable micrometer screw, at one of the two smooth friction rim zones arrows (at the most worn friction rim area).

The following drawing shows the typical grooved wear profile arrows of a perforated gray cast iron brake disc, which has been used to the wear limit, under tough conditions i.e. constant operation mode (test 2. Checking brake discs for minimum thickness 1341

einordnung operation mode). Arrows Zone where most wear occurs in brake disc friction surface A Perforation friction zone (holed friction zone) B smooth friction rim zone top of page

Notes on bedding in the new brake pads

In the case of the perforated (holed) friction plate, the contact pattern of newly installed brake pads adapts more quickly to the wear 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 (beddingin period), their optimum braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking effect must be compensated for by increased pressure on the brake pedal. The same also applies after a brake disc change.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Notes on bedding in the new brake pads

1342

46 53 02 Checking rear PCCB brake discs (wear assessment)

General 1. Visual inspection of the surfaces of the brake disc friction surfaces 2. Checking brake discs for minimum thickness 3. Checking brake discs for edge damage Note concerning bores (perforations) in the brake disc friction surface Note on bedding in the new brake pads Includes: 1. Visual inspection for surface changes in the brake disc friction surfaces (wear assessment). 2. Check brake disc for minimum thickness (wear assessment/max. permissable total wear 0.5 mm) => 2. Checking brake discs for minimum thickness. 3. Check brake discs for edge damage (damage due to improper use) => 3. Checking brake discs for edge damage . top of page

General
Two condition criteria can make replacement necessary depending on the wear of perforated brake discs: 1. Surface changes in the brake 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 cases (for longterm race driving brake loads / very high temperature fluctuations in the friction surfaces), the surface changes can proceed so quickly that a premature disc change has to be performed. top of page

1. Visual inspection of the surfaces of the brake disc friction surfaces

Note The friction surface changes occur due to material fatigue as a result of extremely high thermal load. These disc temperatures which occur above all in racing operation cause a progressive material fatigue. Effects on driving: The surface change worsens the smoothness of braking, decreases the disc strength and increases the brake pad wear and therefore makes a precautionary parts replacement necessary. The following illustrations (PCCB brake disc wear appearance) are to be used for damage assessment.

46 53 02 Checking rear PCCB brake discs (wear assessment)

1343

einordnung

PCCB brake disc wear appearance

A. Friction area surface after normal brake load in street use operation. No replacement necessary!

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 brake discs in the case of connected friction surface damage > 1 cm2 .

top of page

PCCB brake disc wear appearance

1344

einordnung

2. Checking brake discs for minimum thickness

Note For perforated brake discs, the minimum thickness must always be measured on the inner or outer friction surface trace. Brake disc thickness/wear limit: Max. 0.5 mm total wear permissible. Refer to the technical data for the new dimension and other dimensions 46 Technical data/wear limits GT2 or Turbo with PCCB .

Measure the brake disc thickness dimension 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 wear, a brake disc change can be necessary on the brake disc friction surfaces due to edge damage! In this case, only one brake disc can be replaced if the friction area surface of the other PCCB brake disc is in order!

The following criteria applies to edge damage assessment: Max. permissible width/depth = 2 mm! Max. permissible length = 10 mm! 2. Checking brake discs for minimum thickness 1345

einordnung Max. 3 damaged edge areas permissible!

top of page

Note concerning bores (perforations) in the brake disc friction surface

CAUTION PCCB (Porsche Ceramic Composite Brake): Damage of material damage (danger of damage to the brake discs) if improper work is performed on the bores in the brake disc friction surface! Clean the bores on PCCB brake discs with highpressure cleaning equipment (only if necessary). In doing so, observe the environmental and safety regulations! Do not machine (boring or countersinking is not permissible)!

Use highpressure 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 beddingin period for PCCB brake discs than cast iron brake discs. In general, the following applies: New brake pads must be broken in (beddingin period), their optimum braking effect is therefore not until after a few hundred kilometers. The slightly reduced braking effect must be compensated for by increased pressure on the brake pedal. The same also applies after a brake disc change.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

3. Checking brake discs for edge damage

1346

50 10 55 Replacing closing panel

Cutting out closing panel and front floor panel Preparing closing panel and front floor panel for installation and 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 closing panel :

A = closing panel B = front floor panel top of page

Cutting out closing panel and front floor panel

50 10 55 Replacing closing panel

1347

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be 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 before the damaged parts are removed.

No. Procedure Place vehicle on the alignment bench

Instructions Place the vehicle with the units installed at the rear onto the set of straightening attachments and fasten in place. 1348

Cutting out closing panel and front floor panel

einordnung 1 Separating spotwelded joints between the closing panel/side members and the front floor panel Separating spotwelded joints between the closing panel/wheel housings Separating spotwelded joints between the front floor panel and bulkhead at the middle. Separating spotwelded joints between the front floor panel and bulkhead at the sides Separating spotwelded joints between the front floor panel/side members Use the spotweld cutter to separate the spotwelded joints of the closing panel to the side members A, B and the front floor panel C from the outside. Separate the spotwelded joints of the closing panel to the wheel housings from the inside (luggagecompartment side) D with the spotweld cutter. Separate spotwelded joints of the front floor panel to the bulkhead at the middle F from the inside (luggagecompartment side) with the spotweld cutter. Separate the spotwelded joints between the front floor panel and bulkhead at the left and right sides G . Separate spotwelded joints of the front floor panel to the side members on the left and right E from the outside with the spotweld cutter.

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Preparing closing panel and front floor panel for installation and fitting

Preparing closing panel and front floor panel for installation and fitting

1349

einordnung

No. Procedure 1 Preparing spare parts

2 3

Cleaning the welding areas Fitting the front floor panel in the body and fastening it on the straightening attachments. Fitting in wings and front lid

Instructions Remove the factoryapplied primer on the welding areas of the spare parts A, B, C, D, E, F, G using the rotary brush. Drill or punch (with a hole punch) 7 mm holes spaced 20mm apart for plugwelding with shielding gas. => Welding in closing panel and front floor panel Remove underbody coating and paint layers, etc. from the welding areas of the body with a hotair gun or rotary brush. Adjust the spare front floor panel to the side members and to the bulkhead. Fasten the spare front floor panel to the straightening attachment for the frontaxle mount and diagonal brace. Fasten the side members to the straightening attachment for the impact pipes (impact dampers). Fit the left and right wings and fit in the front lid. => Diagram body gap dimensions 1350

Preparing closing panel and front floor panel for installation and fitting

einordnung

top of page

Welding in closing panel and front floor panel

No. Procedure Instructions 1 Plugwelding front floor panel to the Plugweld the front floor panel to the bulkhead at the bulkhead at the middle under shielding gas middle F under shielding gas. 2 Plugwelding front floor panel to the Plugweld radiator tank to the front floor panel G bulkhead under shielding gas on the left and right under shielding gas. 3 Plugwelding the front floor panel to the Align the front floor panel with the side members on side members under shielding gas the left and right E and plugweld under shielding gas.

Welding in closing panel and front floor panel

1351

einordnung 4 Spotwelding the closing panel Spotweld the closing panel to the front floor panel C and the side members on the left and right A, B . Spotweld the closing panels with the wheel housings on the left and right D .

Spotwelding the closing panel to the front floor panel

top of page

Tools and materials

Item Special tool designation 1 Basic straightening attachments for 911 Carrera (996) Nr. 7250700 2 Additional straightening attachments for 996 Turbo Nr. 7250710 3 Star gauges Nr. 1271 4 5 6 7 8 9 10 11 12 13 Shieldinggas welding device Multispot spotwelder Pneumatic body saw Angle grinder Oscillating body saw (special electrical cutter) Multispot spotweld cutter Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm, No. 129

Remarks 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 2.4 Workshop Equipment Manual

996420, 996421, 996450, 996451, 996430, 996840, 996841

Tools and materials

1352

50 14 55 Replacing front wall

Cutting out front wall Preparing 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

Cutting out front wall

50 14 55 Replacing front wall

1353

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be 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 before the damaged parts are removed.

No. Procedure

Instructions => Replacing closing panel 1354

Cutting out front wall

einordnung Cutting out closing panel and front floor panel Place vehicle on the alignment bench Separating spotwelded joints between front wall/side members and wheel housings Separating spotwelded joints between the radiator tank and front wall Separating spotwelded joints and MIG seams between the front wall and side members.

Place the vehicle with the units installed at the rear onto the set of straightening attachments and fasten in place. Separate spotwelded joints of the front wall to the side members A and the wheel housings B with the spotweld cutter. Separate the spotwelded joints of the radiator tank to the front wall from the inside (radiatortank side) C, D with the spotweld cutter. Separate spot welds of the front wall at the bottom to the side member E with the spotweld cutter. Grind off the MIG seams joining the front wall at the sides to the side member F, G with the parting grinder.

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Preparing front wall for installation and fitting

Preparing front wall for installation and fitting

1355

einordnung

No. Procedure 1 Preparing spare parts

2 3

Cleaning the welding areas Inserting the front wall into the body

Instructions Remove the factoryapplied primer on the welding areas of the spare parts A, B, C, D, E, using the rotary brush. Drill or punch (with a hole punch) 7 mm holes spaced 20 mm apart for plugwelding with shielding gas => Welding in front wall Remove underbody coating and paint layers, etc. from the welding areas of the body with a hotair gun or rotary brush. Adjust the spare front wall to the side members and the radiator tank. Fitting of the following parts => Replacing closing panel

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Preparing front wall for installation and fitting

1356

einordnung

Welding in front wall

No. Procedure 1 Plugwelding front wall/side members and wheel housings 2 Plugwelding radiator tank/front wall. 3 Welding the front wall/side members under shielding gas

Instructions Plugweld front wall to the side members and wheel housing A, B under shielding gas. Plugweld radiator tank to the front wall C, D on the left and right. Weld front wall at the bottom to the side member E and front wall at the sides to the side member F, G with a full weld under shielding gas.

top of page Welding in front wall 1357

einordnung

Tools and materials

Item Special tool designation 1 Basic straightening attachments for 911 Carrera (996) 7250700 2 Additional straightening attachments for 996 Turbo 7250710 3 Star gauges 1271 4 5 6 7 8 9 10 11 12 13 Shieldinggas welding device Multispot spotwelder Pneumatic body saw Angle grinder Oscillating body saw (special electrical cutter) Multispot spotweld cutter Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm Nr. 129

Remarks 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Tools and materials

1358

50 74 55 Replacing wheel housing

Removing wheel housing, lower shell and outer side member from the body Preparing wheel housing, lower shell and outer side member for installation and fitting Welding 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 repair "Replacing wheel housings":

A = wheel housing B = lower shell C = outer side member top of page

Removing wheel housing, lower shell and outer side member from the body

50 74 55 Replacing wheel housing

1359

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be followed. 5 Safety instructions 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 before the damaged parts are removed.

No. Procedure Instructions Placing vehicle on the alignment bench Place the vehicle with the units mounted at the rear onto the set of straightening attachments and fasten it in Removing wheel housing, lower shell and outer side memberfrom the body 1360

einordnung position. Separating the spotwelded joint Separate the spotwelded joints between the outer side between the outer/inner side members member and inner side member A, C, D and the front wall B with the spotweld cutter. Separating welds between outer side Grind open the MIG seams between outer side member member and front wall E and the front wall F and the support shell on the floorpan G . Separating the spotwelded joint Separate the spotwelded joint of the wheel housing to the between the wheel housing and closing closing panel H using the spotweld cutter. panel Separating spotwelded joint between Separate spotwelded joint of the lower shell to the wheel lower shell/wheel housing and hinge housing J, E and the hinge pillar I using the pillar spotweld cutter. Separating the spotwelded joint Separate the spotwelded joint (vehicle interior) of the between the wheel housing/ Apillar front wall P and hinge pillar M to the wheel housing and transverse wall using the spotweld cutter. Grind open the MIG seams N, O with the parting grinder. Separate the spotwelded joint of the wheel housing on the outside to the front wall L using the spotweld cutter.

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Preparing wheel housing, lower shell and outer side member for installation and fitting

Preparing wheel housing, lower shell and outer side member for installation and fitting

1361

einordnung

No. Procedure 1 Preparing spare parts

2 3

Cleaning the welding areas Inserting outer side member, wheel housing into the body

Instructions Remove the factoryapplied primer on the welding areas of the spare parts A, B, C, D, E, F, G, H, I using the rotary brush. Drill or punch (with a hole punch) 7 mm holes spaced 20 mm apart for plugwelding with shielding gas. => Welding wheel housing, lower shell and outer side members into the body Remove underbody coating and paint layers, etc. from the welding areas of the body with a hotair gun or rotary brush. Straightening attachment 2 for frontaxle mount or on the straightening attachment 1 for the impact pipes (impact absorbers) must fitted for the fitting work. Fit wheel housing in the body and fasten on straightening attachment 3 . Insert spare outer side member on the inner side member.

4 Preparing wheel housing, lower shell and outer side member for installation and fitting 1362

einordnung Fitting in wings and front Fit the left and right wings and fit in the front lid. lid => Diagram body gap dimensions

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Welding wheel housing, lower shell and outer side members into the body

No. 1

Procedure Instructions Plugwelding wheel housing/hinge pillar, front Weld the spare wheel housing to the front wall and cross member under shielding gas wall N, O with an interrupted full weld under shielding gas. Plugweld the connection to the hinge pillar M and the front wall P, L under 1363

Welding wheel housing, lower shell and outer side members into the body

einordnung shielding gas. Spotwelding the wheel housing Spotweld the wheel housing to the outer side member K . Welding the lower shell under shielding gas Plugweld the lower shell to the wheel housing J, E, I under shielding gas. Welding outer side member under shielding gas Spotweld the outer side member to the and with spot welds inner side member A, D, C . Plugweld the connection to the front wall B under shielding gas. Welding inner/outer side members and front Weld inner side member to outer side wall under shielding gas member E and the front wall F with an interrupted full weld under shielding gas. Welding side member/support shell under Weld side members to the support shell G shielding gas with a full weld under shielding gas.

2 3 4

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Tools and materials

Item Designation of the special tool 1 Basic straightening attachments for 911 Carrera (996) No. 7250700 2 Additional straightening attachments for 996 Turbo No. 7250710 3 Star gauges No. 1271 4 5 6 7 8 9 10 11 12 13 Shieldinggas welding device Multispot spot welder Pneumatic body saw Angle grinder Oscillating body saw (special electrical cutter) Multispot spotweld cutter Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm, No. 129

Explanation 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 2.4 Workshop Equipment Manual

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Tools and materials

1364

50 74 56 Replacing wheel housings and side members (sectional repair)

Cutting out wheel housings and side members Preparing wheel housings and side members for installation and fitting Welding in wheel housings and 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 members :

A Front outer side members B Front inner side member C Front wheel housing top of page

Cutting out wheel housings and side members

50 74 56 Replacing wheel housings and side members (sectional repair)

1365

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be followed. => Safety instructions for raising vehicles => Safety instructions for welding => Safety instructions for sticking => Safety instructions for installation work => Safety instructions for corrosion protection => General information and quality notes Note All straightening work on the body in this area must have been completed before the damaged parts are removed.

Cutting out wheel housings and side members

1366

einordnung

No. Procedure Instructions Remove accessories in the repair area according to the scope of damage existing on the vehicle. Refit alignment bench with the basic straightening attachments according to the structural plans included with the straightening attachments. Position vehicle on alignment bench, align according to the control bores and firmly tighten with the straightening attachment. Additionally fasten alignment bench to the bottom seam of the vehicle with the side clamping claws. Cover all accessories remaining in the vehicle and the neighbouring areas with fireproof covers. Reshape connection area of the sheetmetal parts to be replaced. Expose welding areas Remove underbody coating and paint layers, etc. from the welding areas of the body with the hotair gun or rotary brush. Closing panel and front floor => Replacing closing panel panel already cut out 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 Y = 580 mm . 2 Cutting off inner side member Note: Do not cut through the inner reinforcements arrow when cutting through the inner side members. Remove the damaged sections of the inner/outer side members F with the body saw. Position the cut Y within the specified dimension 580 mm . 3 Cutting off outer side members Do not cut through the inner reinforcements arrow when and shortening to the offset to cutting through the outer side members. the wheel housings Position the cut within the specified dimension Y = 580 mm . Shorten the side members with the body saw and the spotweld cutter, so that there is an offset of dimension X = 50 mm between the inner/outer side members and the wheel housing.

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Preparing wheel housings and side members for installation and fitting

Preparing wheel housings and side members for installation and fitting

1367

einordnung

No. Procedure 1 Preparing spare parts

Cleaning the welding areas

Instructions Transfer cut to the spare front wheel housings and then cut to size. Cut the spare side members to size with the body saw and then fit so that there is an offset of dimension X = 50 mm between the inner and outer side members. Remove the factoryapplied 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 plugwelding under shielding gas. => Welding in wheel housings and side members Remove underbody coating and paint layers, etc. from the welding areas of the body with a hotair gun or rotary brush. 1368

Preparing wheel housings and side members for installation and fitting

einordnung 3 Fitting the side members and wheel Fasten the spare innner side member on the straightening housing in the body and fastening attachment for the frontaxle mount or on the straightening them on the straightening attachments. attachments for the impact pipes (impact absorbers) and fit it in. Fitting in front wall => Replacing front wall Fitting the front floor panel in the => Replacing closing panel body and fastening it on the straightening attachment. Fitting in wings and front lid Fit the left and right wings and fit in the front lid. => Gap dimensions, body front

4 5

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Welding in wheel housings and side members

Welding in wheel housings and side members

1369

einordnung Note When butt welding body sheet panels with a sheet thickness of > 1.5 mm, there must be a welding slit width s = 1 x sheet thickness to guarantee the required welding quality (welding through).

No. 1 2

Procedure Welding in the inner side member. Welding in wheel housings.

Welding in the outer side member.

4 5

Welding in front wall Welding in closing panel and front floor panel Removing vehicle from the alignment bench

Instructions Weld the inner side member with a full butt weld F under shielding gas. Spotweld wheel housings and inner side members A . Weld the wheel housing from the outside with a full butt weld B under shielding gas. Spotweld the outer side member to the inner side member H, I . Weld the outer side member with a full butt weld F under shielding gas. => Welding in front wall => Welding in closing panel and front floor panel

Detach side clamping jaws and straightening attachments on the vehicle. Remove vehicle from the alignment bench. Cleaning spotwelded joints and Clean spotwelded joints and sheetmetal flanges with a sheetmetal flanges with a wire brush wire brush. Grind shielding gas weld area visible after installation, apply body solder to connectors to body and align. Prime flange areas 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. Supplement cavity preservation. Install removed accessories in the repair area.

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Materials and tools

Item Special tool designation 1 Basic straightening attachments for 911 Carrera (996) Nr. 7250700 2 Additional straightening attachments for 911 Turbo (996) Nr. 7250710 3 Star gauges Nr. 1271

Remarks 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 1370

Materials and tools

einordnung 4 5 6 7 8 9 10 11 12 13 Shieldinggas welding device Multispot spotwelder Pneumatic body saw Angle grinder Oscillating body saw (special electrical cutter) Multispot spotweld cutter Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm Nr. 129 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 2.4 Workshop Equipment Manual

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Materials and tools

1371

50 79 55 Replacing front inner side member

Removing front inner 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 side member

50 79 55 Replacing front inner side member

1372

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be followed. => Safety instructions for raising vehicles => Safety instructions for welding => Safety instructions for sticking => Safety instructions for installation work => Safety instructions for corrosion protection => General information and quality notes Note All straightening work on the body in this area must have been completed before the damaged parts are removed.

Removing front inner side member

1373

einordnung

No.

1 2 3

Procedure Instructions Remove accessories in the repair area according to the scope of damage existing on the vehicle. Refit alignment bench with the basic straightening attachments according to the structural plans included with the straightening attachments. Position vehicle on alignment bench, align according to the control bores and firmly tighten with the straightening attachment. Additionally fasten alignment bench to the bottom seam of the vehicle with the side clamping claws. Cover all accessories remaining in the vehicle and the neighbouring areas with fireproof covers. Reshape connection area of the sheetmetal parts to be replaced. Expose welding areas Remove underbody coating and paint layers, etc. from the welding areas of the body with the hotair gun or rotary brush. Replacing closing panel => Replacing closing panel Replacing wheel housing => Replacing wheel housing Replacing front wall => Replacing front wall Disconnecting web plate Cut through the shielding gas weld A on the connection of the web plate to the firewall. Separating inner side Separate the spotwelded joints B, C using the spotweld cutter. member Cut through the shielding gas weld G using the parting grinder. Separating lower side Cut through the shielding gas weld E, F to the bottom floor of member side member.

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Preparing and fitting the front inner side member for installation

Preparing and fitting the front inner side member for installation

1374

einordnung

No. Procedure 1 Cleaning the welding areas

3 4

Instructions Remove the factoryapplied primer on the welding areas of the spare parts A, B, C, D, E, F, G, X using the rotary brush. Drill or punch (with a hole punch) 7 mm holes spaced 20mm apart for plugwelding with shielding gas. => Welding in front inner side member Cleaning welding and sealing Remove underbody coating and paint layers, etc. from the welding areas areas of the body with the hotair gun or rotary brush. Coat single point flange areas All single point flange areas which will not receive a body adhesive with zincrich varnish. application should be coated with a zincrich varnish A, B, C, D, E, F, G, X . Reinforcement spot welding Spotweld the reinforcement X and the side member with six spotwelds. Inserting the side member Straightening attachment arrow for frontaxle mount or on the into the body impact pipe (impact absorber) arrow must be screwed on for the 1375

Preparing and fitting the front inner side member for installation

einordnung fitting work. Fit the web plate on the inner side member. Drill open the firewall from inside (passenger compartment) using drill bit 7 mm.

5 6

Fitting web plate Drilling through firewall

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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 width s = 1x sheet thickness to guarantee the required welding quality (welding through).

Welding in front inner side member

1376

einordnung

No. Procedure 1 Spotwelding inner side member/web plate 2 3 Welding inner firewall/side member under shielding gas Welding inner side member/ base side member under shielding gas. Inner side member/firewall

Instructions Spotweld web plate to side member B, C . Weld the connection to firewall A with an interrupted butt weld seam under shielding gas. Plugweld the predrilled holes D from the firewall to inner side member. Weld the inner side member/base side member with a full butt weld F, E under shielding gas.

Weld inner side member/firewall G with interrupted weld seam under shielding gas. Replacing front wall => Replacing front wall Replacing wheel housing => Replacing wheel housing Replacing closing panel => Replacing closing panel Removing vehicle from the Detach side clamping jaws and straightening attachments on the alignment bench vehicle. Remove vehicle from the alignment bench. Cleaning spotwelded joints and Clean spotwelded joints and sheetmetal flanges with a wire sheetmetal flanges with a wire brush. Grind shielding gas weld area visible after installation, brush apply body solder to connectors to body and align. Prime flange areas 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. Supplement cavity preservation. Install removed accessories in the repair area.

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Materials, tools

Item 1 2 2 3 4 5 6 7 Materials, tools

Designation of the special tool Straightening attachments 996 Carrera Additional straightening attachments for 996 Turbo Star gauges 1271 MIG welder Multispot spotwelder Pneumatic body saw Angle grinder

Remarks Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual 1377

einordnung Oscillating body saw (special electrical cutter) Multispot spotweld cutter Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm 129

8 9 10 11 12

Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Materials, tools

1378

50 93 30 Cleaning front water drains on Coup and Cabriolet

Cleaning front water drains on Coup and Cabriolet

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Cleaning front water drains on Coup and Cabriolet

50 93 30 Cleaning front water drains on Coup and Cabriolet

1379

einordnung

CAUTION Material damage due to water leakage! Water drainage hoses can be pushed out or pressed in when blown out of the body The water drains should be blown out carefully with compressed air.

No.

Procedure Removing cowl panel cover Blow out water drains on right side of front end

Instructions 702219 Removing and installing cowl panel cover Carefully blow out water drainage 1 from top inset A on right side of front of vehicle. Remove dirt particles from the radiator tank inset B with the vacuum cleaner.

Cleaning front water drains on Coup and Cabriolet

1380

einordnung 2 Blow out water drains on right side of front end Carefully blow out water drainage 2 from top inset A on right side of front of vehicle. Remove dirt particles from the radiator tank inset B with the vacuum cleaner. Blow out water drainage on Put vehicle onto platform lift and carefully blow out the left water left side of front end. drainage 3 inset B from the outside of the wheel arch. Remove dirt particles from the radiator tank inset B with the vacuum cleaner. Blow out water drainage on Put vehicle onto platform lift and carefully blow out the left water left side of front end. drainage 4 inset A from the outside of the wheel arch. Remove dirt particles from the radiator tank inset B with the vacuum cleaner. Installing cowl panel cover 702219 Removing and installing cowl panel cover

996430, 996431, 996630, 996631, 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Cleaning front water drains on Coup and Cabriolet

1381

51 03 55 Replacing roof
Removing 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

51 03 55 Replacing roof

1382

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be followed. => Safety instructions for raising vehicles => Safety instructions for welding => Safety instructions for sticking => Safety instructions for installation work => Safety instructions for corrosion protection => General information and quality notes Note All straightening work on the body in this area must have been completed before the damaged parts are removed. Removing roof 1383

einordnung

No. Procedure Instructions Remove accessories in the repair area according to the scope of damage existing on the vehicle. Refit alignment bench with the basic straightening attachments according to the structural plans included with the straightening attachments. Position vehicle on alignment bench, align according to the control bores and firmly tighten with the straightening attachment. Additionally fasten alignment bench to the bottom seam of the vehicle with the side clamping claws. Cover all accessories remaining in the vehicle and the neighbouring areas with fireproof covers. Reshape connection area of the sheetmetal parts to be replaced. Expose welding areas Remove underbody coating and paint layers, etc. from the welding areas of the body with the hotair gun or rotary brush. 1 Separating the spotwelded Separate the spotwelded joints between the outer roof panel and joints between the outer roof the outer side section C, D and on the cowl panel frame A panel/outer side section with the spotweld cutter. 2 Separating the spotwelded Separate the spotwelded joint between the outer roof panel and joints between the outer roof the rear roof frame B with the spotweld cutter. panel/rear roof frame Heat up the bonded joint between the outer roof panel and the 3 Separating the bonded joint between the cowl panel frame cowl panel frame or the rear roof frame with the hotair gun. on the outer roof panel/rear roof Insert a metal spatula between the bonded joints and separate them. Lift the outer roof panel upwards out of the body. frame

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Preparation of roof for installation and fitting

Preparation of roof for installation and fitting

1384

einordnung

No. Procedure Instructions 1 Preparing spare part Remove the factoryapplied primer on the welding areas of the spare part A, B, C, D using the rotary brush. 2 Cleaning the Remove underbody coating and paint layers, etc. from the welding areas of welding areas the body with a hotair gun or rotary brush. 3 Fitting the outer Insert outer roof panel into the body. roof panel 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 points on the outer roof panel and the outer side section. 4 Installing roof joint As a check, install the roof joint strips on the left and right. strips 663619 Removing and installing roof joint strip. If necessary, recenter outer roof panel.

Preparation of roof for installation and fitting

1385

einordnung top of page

Welding in roof

CAUTION Observe the working time of the adhesive! The new part must be welded in within 30 minutes. Otherwise the adhesion of the adhesive is impaired.

No. 1

Procedure Applying adhesive

Instructions => Tools and materials Observe the working time of the adhesive: 1386

Welding in roof

einordnung apply the adhesive evenly to the inside of the cowl panel frame and the rear roof frame as a triangular bead dimension X = approx. 8 mm . Spot welding the outer roof Spotweld the outer roof panel to the outer side section panel/outer side section C, D . Ensure that the spotwelding is carried out within the corrugated cutout of the inner roof frame E . Spot welding the outer roof Spotweld the outer roof panel to the rear roof frame panel/rear roof frame B . Removing vehicle from the Detach side clamping jaws and straightening alignment bench attachments on the vehicle. Remove vehicle from the alignment bench. Cleaning spotwelded joints and Clean spotwelded joints and sheetmetal flanges with a sheetmetal flanges with a wire brush wire brush. Grind shielding gas weld area visible after installation, apply body solder to connectors to body and align. Prime flange areas 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. Supplement cavity preservation. Install removed accessories in the repair area.

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Tools and materials

Item Special tool designation 1 Teromix6700 2component adhesive 2 Teromix processing nozzle

3 4 5 6 7 8 9 10

Basic straightening attachments for 911 Carrera (996) Star gauges 1271 MIG welder Multispot spotwelder Multispot spotweld cutter Pneumatic body saw Angle grinder Oscillating body saw (special electrical cutter)

Remarks Spare part Gr. 8; Parts Catalogue Manufacturer: Henkel Teroson GmbH Postfach 10 56 20 69046 Heidelberg HansBunteStrae 4 Tel.: (066221) 7040 Fax: (066221) 704585 Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual

Tools and materials

1387

einordnung 11 12 13 14 Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm 129 Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual

996420, 996430, 996431, 996840, 996841

Tools and materials

1388

51 21 55 Replacing rear centre panel

Removing rear centre panel Preparing the rear 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 panel top of page

Removing rear centre panel

51 21 55 Replacing rear centre panel

1389

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be followed 5 Safety instructions 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 before the damaged parts are removed.

No. 1

Procedure Instructions Separate the spotwelded joint Separate the spotwelded joint between the outer rear centre on the rear window aperture panel, the rear centre panel lock plate and the 1390

Removing rear centre panel

einordnung convertibletop rest cross member A, B with the spotweld cutter. When loosening the connection A , both the body panels (rear centre panel and rear centre panel lock plate) must be cut open. Separate rear centre panel from Cut through the brazed seam C on the connection to the side section side section with the parting grinder. Remove the rear centre panel At the factory, the rear centre panel is sealed to the convertibletop rest cross member with an expanded sealant on the left and right arrows . This seal is destroyed when replacing the rear centre panel and must be replaced.

2 3

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Preparing the rear centre panel for installation and fitting

Preparing the rear centre panel for installation and fitting

1391

einordnung

No. Procedure 1 Clean the welding areas 2 Prepare spare part 3 Set gap 4 Insert seal

Insert the rear centre panel

Instructions Remove the factoryapplied primer on the welding areas of the spare part A, B, C using the rotary brush. Remove underbody coating and paint layers, etc. from the welding areas of the body with a hotair gun or rotary brush. Set the gap between the side sections and the rear lid => Diagram body gap dimensions 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 foam. Apply another triangular bead dimension "X" = approx. 15 mm of body sealant into the impression on the underside of the convertibletop rest cross member E . Set the gap between the side sections and the rear lid => Diagram body gap dimensions

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Welding in the rear centre panel

Welding in the rear centre panel

1392

einordnung

No. Procedure Instructions 1 Spotweld the rear centre panel Spotweld the connection between the rear centre panel and the convertibletop rest cross member, top A or bottom B . 2 Weld the connection to the side Weld the overlap of the connection to the side section with a full section under shielding gas. weld C of approx. 15 mm under shielding gas.

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Tools and materials

Item 1

Tools Star gauges Nr. 1271

Explanation Gr. 2.4; Workshop Equipment Manual

Tools and materials

1393

einordnung 2 3 4 5 6 7 8 9 10 11 MIG welder Multispot spotwelder Pneumatic body saw Angle grinder Oscillating body saw (special electrical cutter) Multispot spotweld cutter Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm Nr. 129 Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Tools and materials

1394

51 45 55 Replacing lower side member

Cutting out lower side member Preparation for installation 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 member top of page

Cutting out lower side member

51 45 55 Replacing lower side member

1395

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be followed. 5 Safety instructions 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 before the damaged parts are removed.

No. Procedure Instructions 1 Separating the spotwelded joint Separate the spotwelded joint between the outer lower side between the outer/inner lower member and the inner lower side member A with the Cutting out lower side member 1396

einordnung side members spotweld cutter. Cut through the connection to the Apillar B with the body saw. Position the cut so that the spare body part (outer lower side member) overlaps Apillar by approx. 60 mm. Cut the connection to the side section E with the body saw. Position the cut so that the spare body part (outer lower side member) overlaps the side section by approx. 60 mm. Sawing through the web plate Cut through the web plate at the top and bottom F, G with the body saw. Separating the spotwelded joint Separate the spotwelded joint between the outer lower side between the outer/inner lower member and the inner lower side member C with the side members spotweld cutter. Separating the spotwelded joint Separate the spotwelded joint between the web plate and the between the web plate/inner inner lower side member D with the spotweld cutter. lower side member

2 3

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Preparation for installation of lower side member and fitting

Preparation for installation of lower side member and fitting

1397

einordnung

No. Procedure 1 Cleaning the welding areas 2 Preparing spare part 3

4 5

Instructions Remove the factoryapplied primer on the welding areas of the spare part A, B, C, D, E using the rotary brush. Remove underbody coating and paint layers, etc. from the welding areas of the body with a hotair gun or rotary brush. Inserting outer lower side Insert outer lower side member into the body. member Cut through the outer lower side member, overlapping at the separation Fitting lower side member point, flush with the Apillar B with the body saw. separation point Fitting lower side member Cut through the outer lower side member, overlapping at the separation separation point point, flush with the side section E with the body saw. Setting gap Set gap between door and outer lower side member. 5 Body gap dimensions

Preparation for installation of lower side member and fitting

1398

einordnung top of page

Welding in lower side member

No. Procedure 1 Welding outer/inner lower side members under shielding gas

2 3

Welding the web plate under shielding gas Welding outer/inner lower side members under shielding gas

Instructions Plugweld the outer lower side member to the inner lower side member A under shielding gas. Weld the connection to the Apillar B and the connection to the side section E with a full weld under shielding gas. Weld the web plate and the inner lower side member D together with an interrupted full weld under shielding gas. Plugweld the outer lower side member and the inner lower side member C together under shielding gas.

Welding in lower side member

1399

einordnung top of page

Tools and materials

Item 1 2 3 4 5 6 7 8 9 10

Designation of the special tool Star gauges Nr. 1271 MIG welder Pneumatic body saw Angle grinder Oscillating body saw (special electrical cutter) Multispot spotweld cutter Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm Nr. 129

Explanation 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Tools and materials

1400

51 45 55 Replacing lower side member Cabriolet

Cutting out lower side member Preparation for installation 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 top of page

Cutting out lower side member

51 45 55 Replacing lower side member Cabriolet

1401

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be followed. => Safety instructions for raising vehicles => Safety instructions 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, 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. Cutting out lower side member 1402

einordnung

No. Procedure 1 Separating the spotwelded joint between the outer/inner lower side members

2 3

Sawing through the web plate Separating the spotwelded joint between the outer/inner lower side members Separating the spotwelded joint between the web plate/inner lower side member

Instructions Cut through the spotwelded joint between the outer lower side member and the inner lower side member A or between the outer lower side member and the Apillar B with the spotweld cutter. Cut through the connection to the side section E with the body saw. Position the cut so that the spare body part (outer lower side member) overlaps the side section by approx. 60 mm. Cut through the web plate at the top and bottom F, G with the body saw. Separate the spotwelded joint between the outer lower side member and the inner lower side member C with the spotweld cutter. Separate the spotwelded joint between the web plate and the inner lower side member D with the spotweld cutter.

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Preparation for installation of lower side member and fitting

Preparation for installation of lower side member and fitting

1403

einordnung

No. Procedure 1 Cleaning the welding areas 2 Preparing spare part 3 4 5

Instructions Remove the factoryapplied primer on the welding areas of the spare part A, B, C, D, E using the rotary brush. Remove underbody coating and paint layers, etc. from the welding areas of the body with a hotair gun or rotary brush. Inserting outer lower side Insert outer lower side member into the body. member Fitting lower side member Cut through the outer lower side member, overlapping at the separation separation point point, flush with the side section E with the body saw. Setting gap Set gap between door and outer lower side member. => Gap dimensions, body centre

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Preparation for installation of lower side member and fitting

1404

einordnung

Welding in lower side member

No. Procedure Instructions 1 Welding outer/inner lower side Plugweld the outer lower side member and the inner lower side members under shielding gas member A as well as the connection to the Apillar B with shielding gas. Weld the connection to the side section E with a continuous full weld under shielding gas. 2 Welding the web plate under Weld the web plate and the inner lower side member D shielding gas together with an intermittent full weld under shielding gas. 3 Welding outer/inner lower side Plugweld the outer lower side member and the inner lower side members under shielding gas member C together under shielding gas.

Welding in lower side member

1405

einordnung top of page

Tools and materials

Item 1 2 3 4 5 6 7 8 9 10

Special tool designation Star gauges no. 1271 MIG welder Body saw Angle grinder Oscillating body saw (special electrical cutter) Multispot spotweld cutter Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm no. 129

Remarks 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual 3 Workshop Equipment Manual 3 Workshop Equipment Manual 2.4 Workshop Equipment Manual

996630, 996631, 996620, 996621, 996650, 996651

Tools and materials

1406

51 63 19 Removing and installing deformation element

Removing deformation element Installing deformation element

top of page

Removing deformation element

705719 Removing the Apillar trim

51 63 19 Removing and installing deformation element

1407

einordnung

1. Boring out deformation element Drill out the pop rivets 1 using a 4 mm drill and remove the deformation element A . top of page

Installing deformation element

WARNING Danger of injury by damaged deformation elements after an accident! 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 Position deformation element A on inner cowl panel frame and rivet down using the pop rivets 1 . 705719 Installing Apillar trim

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Removing deformation element

1408

51 87 55 Replacing seat cross member

Cutting out seat cross member Preparation of seat 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 top of page

Cutting out seat cross member

51 87 55 Replacing seat cross member

1409

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be followed. => Safety instructions for raising vehicles => Safety instructions for welding => Safety instructions for sticking => Safety instructions for installation work => Safety instructions for corrosion protection => General information and quality notes Note All straightening work on the body in this area must have been completed before the damaged parts are removed.

Cutting out seat cross member

1410

einordnung

No.

Procedure Instructions Remove accessories in the repair area according to the scope of damage existing on the vehicle. Cover all accessories remaining in the vehicle and the neighbouring areas with fireproof covers. Reshape connection area of the sheetmetal parts to be replaced. Expose welding areas Remove underbody coating and paint layers, etc. from the welding areas of the body with the hotair gun or rotary brush. Separating spotwelded joints between the Separate the spotweld joints between the seat seat cross member and floorpan cross member and the floorpan A, B with the spotweld cutter. Separating spotwelded joints between the Separate the spotweld joints C between the seat cross member and inner member seat cross member and inner member with the spotweld cutter. Separating spotwelded joints between the Separate the spotwelded joints D, E, F seat cross member and inner member between the seat cross member and inner lower side member with the spotweld cutter.

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Preparation of seat cross member for installation and fitting

Preparation of seat cross member for installation and fitting

1411

einordnung

No. Procedure 1 Preparing spare parts

2 3

Cleaning the welding areas Measuring seat cross member

Instructions Remove the factoryapplied primer on the welding areas of the spare parts A, B, using the rotary brush. Drill or punch (with a hole punch) 7 mm holes spaced 20mm apart for plugwelding with shielding gas. => Welding in seat cross member Remove underbody coating and paint layers, etc. from the welding areas of the body with the hotair gun or rotary brush. Measure the seat cross member at the front screwed points (hole center) forward to the hole edge of the reinforcement in the floorpan dimension X = 405 mm dimension Y = 453 mm

top of page Preparation of seat cross member for installation and fitting 1412

einordnung

Welding in seat cross member

No. Procedure Instructions 1 Plugwelding seat cross Plugweld the seat cross member at the front and rear A, B member under shielding gas under shielding gas. 2 Plugwelding seat cross Plugweld the seat cross member at the sides C under member under shielding gas shielding gas. 3 Plugwelding seat cross Plugweld the seat cross member at the sides and middle D, E, member under shielding gas F under shielding gas. Cleaning spotwelded joints Clean spotwelded joints and sheetmetal flanges with a wire and sheetmetal flanges with a brush. Grind shielding gas weld area visible after installation, wire brush apply body solder to connectors to body and align. Prime flange areas with 2K primer. Welding in seat cross member 1413

einordnung Restore standard sealing with body sealant. Paint exterior outer parts and neighbouring areas. Restore standard undersealing protection with permanent undersealing protection agent. Supplement cavity preservation. Install removed accessories in the repair area.

top of page

Tools and materials

Item 1 2 3 4 5 6 7 8 9 10

Designation of the special tool Star gauges 1271 MIG welder Pneumatic body saw Angle grinder Oscillating body saw (special electrical cutter) Multispot spotweld cutter Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm 129

Remarks Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Tools and materials

1414

51 90 19 Removing and installing underside panel

Removing and installing front cover Removing and installing middle cover Removing and installing rear trim

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Removing and installing front cover

51 90 19 Removing and installing underside panel

1415

einordnung

No. Designation 1 Plastic nut 2 Clip

Qty. Removal 4 6 Insert a narrow screwdriver sideways into the clip and press out. 1 6 1 1 Remove from underside panel middle.

3 4 5 6

Underside panel front Expanding rivet Masking panel left Masking panel right

Installation Check, if necessary, replace. Check, if necessary, replace. The clip must lock with an audible click. Insert in the middle of the underside panel. Check, if necessary, replace.

Removing and installing front cover

1416

einordnung top of page

Removing and installing middle cover

No. 1 2 3

Designation Plastic nut Side underside panel Underside panel middle

Qty. Removal 10 1 1 Remove from underside panel front and rear.

Installation Check, if necessary, replace. Insert in the underside panel front and rear.

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Removing and installing middle cover

1417

einordnung

Removing and installing rear trim

No. 1 2 3

Designation Plastic nut Fastening screw Underside panel rear

Qty. Removal 4 6 1 Remove from underside panel middle.

Installation Check, if necessary, replace. Insert in the middle of the underside panel.

996420, 996421, 996450, 996451, 996630, 996631, 996620, 996621, 996650, 996651, 996430, 996431

Removing and installing rear trim

1418

53 05 55 Replacing rear closing panel

Cutting 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

53 05 55 Replacing rear closing panel

1419

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be followed 5 Safety instructions 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 before the damaged parts are removed.

No. Procedure Place vehicle on the alignment bench Cutting out rear closing panel

Instructions Place the vehicle with the units mounted at the front onto the set of straightening attachments and fasten it in position. 1420

einordnung 1 2 3 Separate the spotwelded joint at the rear closing panel. Separate the spotwelded joint at the rear closing panel. Separate the spotwelded joint on the engine mount at top Separate the spotwelded joint on the engine mount at bottom Use a spotweld cutter to separate the connection between the inner side members and the rear closing panel A on the left and right. Use the spotweld cutter to separate the connection between the side section on the inside and the rear closing panel B, C . Separate the spotwelded joint between the engine mount at top D and the inner side member and the connection to the inner side section F with the spotweld cutter. Use the spotweld cutter to separate the spotwelded joint between the engine mount at bottom E and the inner side member.

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Preparing the rear closing panel for installation and fitting

Preparing the rear closing panel for installation and fitting

1421

einordnung No. 1 Procedure Prepare spare parts Instructions Remove the factoryapplied primer on the welding areas of the spare parts A, B, C, D, E using the rotary brush. Drill or punch (with a hole punch) 7 mm holes spaced 20 mm apart for plugwelding with shielding gas => Welding in rear closing panel Clean the welding areas Remove underbody coating and paint layers, etc. from the welding areas of the body with a hotair gun or rotary brush. Insert the closing panel into Insert the closing panel spare part into the body and fasten it to the body the straightening attachments. If necessary, align it with the inner side sections and the side members. Fit addon parts and check Fit the lid and set the gap dimensions gap dimensions => Diagram body gap dimensions => Removing and installing rear lid Fit the lower part of the lid lock at the rear => Removing and installing lower part of lid lock and check whether the upper part of the lock engages in the lower part of the lock.

2 3

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Welding in rear closing panel

Welding in rear closing panel

1422

einordnung

No. 1

Instructions Plugweld the reinforcement between the side members at bottom E and the closing panel under shielding gas. Spotweld the rear closing panel/side Spotweld the connection between the inner member on the inside side members B, C and the rear closing panel on the left and right. Plugweld the engine mount/side member at Plugweld the engine mounts at the left and top under shielding gas right to the side member at top D under shielding gas. Plugweld the connection F to the inner side section with an approx.10 mm full weld. Spotweld the closing panel/side members Plugweld the connection between the inner on the inside side members A and the closing panel under shielding gas. 1423

Procedure Plugweld reinforcement/side member at bottom under shielding gas

Welding in rear closing panel

einordnung

top of page

Tools and materials

Item 1 2 3 4 5 6 7 8 9 10 11 12 13

Tools Basic straightening attachments for 911 Carrera (996) Additional straightening attachments for 996 Turbo Star gauges Nr. 1271 MIG welder Multispot spotwelder Pneumatic body saw Angle grinder Oscillating body saw (special electrical cutter) Multispot spotweld cutter Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm Nr. 129

Explanation Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual

996420, 996421, 996450, 996451, 996840, 996841

Tools and materials

1424

53 55 55 Replacing side section

Cutting through 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 side section

53 55 55 Replacing side section

1425

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be followed 5 Safety instructions 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 before the damaged parts are removed.

No. Procedure 1 Separate the spotwelded joint on the Bpillar Cutting through side section

Instructions Separate the spotwelded joint between the side section and the inner side section A with the spotweld cutter. Cut off the lower 1426

einordnung side member H so that the spare body part (side section) overlaps the lower side member by approx. 60 mm. Separate the spotwelded joint between the side section C and the lower side member B or wheel housing with the spotweld cutter. Trim the side section at the Bpillar centre with the body saw making a cut G so that the spare body part overlaps the centre of the Bpillar by approx. 60 mm. Trim the side section at the Cpillar with the body saw making a cut F so that the spare body part overlaps the Cpillar by approx. 60 mm. Separate the spotwelded joint on the side window aperture of the rear window D using the spotweld cutter.

Separate the spotwelded joint on the lower side member and the wheel housing Cut through centre of Bpillar Cut through side section at Cpillar Separate the spotwelded joint on the side window aperture

Cutting through side section

1427

einordnung No. Procedure 6 Separate the spotwelded joint of the rear window aperture 7 Separate side section from rear centre panel Instructions Separate the spotwelded joint between the side section of the rear window aperture and the inside of the side section E with the spotweld cutter. Separate the spotweld joint of the overlapping rear centre panel at the top 2 using the spotweld cutter. Cut through the shielding gas weld 1 on the connection to the lower side section with the parting grinder. Separate the spotwelded Separate the spotwelded joint between the light housing and the joint on the light housing inside of the side section 3 and the rear transverse lock panel connection F with the spotweld cutter. Remove side section The side section is sealed from the light housing to the rear centre panel connection in the factory using an expanded sealant. This seal 4 is destroyed when replacing the side section and must be replaced.

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Preparing side section for installation and fitting

Preparing side section for installation and fitting

1428

einordnung

No. Procedure Instructions 1 Clean welding Remove the factoryapplied primer on the welding areas of the spare parts A, and sealing areas B, C, D, E, F, G, H, I using the rotary brush. Drill or punch (with a hole punch) 7 mm holes spaced 20 mm apart for plugwelding with shielding gas => Welding in the side section 2 Clean the welding Remove underbody coating and paint layers, etc. from the welding areas of the areas body with the hotair gun or rotary brush. 3 Adapt the side Fit the side section to the body. Insert door and rear lid to check the body section to the contour. Adjust the gap dimensions between the door and rear lid and the body body => Diagram body gap dimensions 4 Fit side section Cut through both panels at the separation points where the side section overlaps separation points the lower side member I , Cpillar G and Bpillar centre H using the body saw. 5 Insert seal Preparing side section for installation and fitting 1429

einordnung Apply a triangular bead of body sealant dimension "X" = approx. 12 mm high on all sides of the seal. Apply seal to the prepared holes on the inner side section, position the pins at the seal and press into place.

CAUTION Observe the working time of the adhesive (Items 5 and 6)! The new part must be welded in within 30 minutes. Otherwise the adhesion of the adhesive is impaired.

No. 6

Procedure Bond light housing with the inside of the side section

Apply adhesive to the wheel arch up to the start of the side member Tackweld side section under shielding gas

Instructions Apply a triangular bead of adhesive (Teromix6700) dimension "X" = approx. 10 mm high on the connection from the light housing to the inside of the side section. The light housing must lie flush with the side section. Apply the adhesive as a triangular bead dimension "X" = approx. 8 mm on the inside of the side section, along the wheel arch up as far as the start of the side member. 1. On the inside of the side section, in the corner area, apply approx. 40 x 10 mm a triangular bead of body sealant dimension "X" = approx. 12 mm . 2. Insert side section into the body. Check the contours and gap dimensions. => Diagram body gap dimensions Tackweld the side section under shielding gas at the separation points.

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Welding in the side section

Welding in the side section

1430

einordnung

No. 1

Procedure Weld the Bpillar under shielding gas

2 3

Weld Bpillar and Cpillar under shielding gas Spotweld wheel arch and lower side member under shielding gas Spotweld side window aperture

Instructions Plugweld the Bpillar side section to the inside of the side section A under shielding gas. Weld the lower side member connection on the side section to the lower side member I with a continuous butt weld under shielding gas. Weld Bpillar H and Cpillar G with a continuous butt weld under shielding gas. Plugweld underside of lower side member B . Spotweld wheel arch C . Spotweld the side window aperture to the inside of the side section D .

Welding in the side section

1431

einordnung

No. Procedure 5 Spotweld rear window aperture 6 Spotweld light housing

Instructions Spotweld the rear window aperture to the inside of the side section E . Spotweld light housing with the connecting angle and the connection to the transverse lock panel F . On the inside of the side section (small figure), make sure that the welding nuts are lined up with the hole pattern in the side section. Screw in M6 hexagonhead bolts to position. Spotweld the connection with the side section 3 . Plugweld the top connection of the rear centre panel to the side section 2 under shielding gas. Weld the lower connection with a continuous butt weld of approx. 20 mm 1 under shielding gas.

Weld the rear centre panel under shielding gas

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Welding in the side section

1432

einordnung

Flanging the wheel arch edges

GT2

The Turbo Design wheels 12J x 18 ET 45 with 315/30 TR 18 tyres finish almost flush with the wing apertures. Rework on the wheelarch edges is only necessary with the abovementioned wheel dimensions. CAUTION Paint damage can occur in the event of improper reworking of the wing seam! Only carry out reworking on painted wings when the wing seam is partially warmed. Partial painting is required if the conditions are unfavourable.

1. Reworking the wing seam In the areas shown A = approx. 50 mm , B = approx. 295 mm , C = approx. 25 mm , the wing seam and, if 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 the rear spoiler protrudes beyond the flanged side section, the protruding material of the rear spoiler arrow, inset X must be ground or cut away. top of page

Tools and materials

Item 1 2 3 4 5

Tools Basic straightening attachments for 911 Carrera (996) Additional straightening attachments for 996 Turbo Star gauges Nr. 1271 MIG welder Multispot spotwelder GT2

Explanation Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual 1433

Flanging the wheel arch edges

einordnung 6 7 8 9 10 11 12 13 14 Pneumatic body saw Angle grinder Oscillating body saw (special electrical cutter) Multispot spotweld cutter Hole punch Hotair gun Rotary brush Spotweld cutter 7 mm Nr. 129 Teromix6700 2component adhesive Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual Spare part Gr 8; Parts Catalogue; Manufacturer: Henkel Teroson GmbH Postfach 10 56 20 69046 Heidelberg HansBunteStrae 4 Spare part Gr 8; Parts Catalogue; Manufacturer: Henkel Teroson GmbH Postfach 10 56 20 69046 Heidelberg HansBunteStrae 4

15

Teromix processing nozzle

996840, 996841, 996420, 996421, 996450, 996451, 996430, 996431

Tools and materials

1434

53 93 30 Cleaning rear water drains on Coupe and Cabriolet

Cleaning rear water drains on Coupe and Cabriolet Illustrated on the 911 Carrera Coupe and Cabriolet (996)

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Cleaning rear water drains on Coupe and Cabriolet

53 93 30 Cleaning rear water drains on Coupe and Cabriolet

1435

einordnung

CAUTION Material damage due to water leakage! Water drainage hoses can be pushed out or pressed in when blown out of the body. The water drains should 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 sidepanel lining 707519 Removing rear wheel housing liners => Removing and installing wheel housing liners, rear 1 Cleaning rear water drains on Coupe and Cabriolet 1436

einordnung Blowing out the water drain tube in the rear wheel housings on the left and right. Carefully blow out the water drain tube A in the water collection tray on the left and right. Remove any dirt particles from the water collection tray using the vacuum cleaner B . Installing sidepanel lining 707519 Blowing out the water drainage Water drainage hose: hoses from the sliding/tilting roof at Carefully blow out the front water drainage hose in the the front, rear, left and right. Bpillar A . Rear water drainage hose: Put vehicle onto lifting platform and carefully blow out the water drain A on the left and right in the rear wheel housing from the outside of the wheel arch. Open sliding/tilting roof and remove dirt particles from the sliding roof frame using the vacuum cleaner. => Removing and installing wheel housing liners, rear

Installing wheel housing liner

996430, 996431, 996630, 996631, 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Cleaning rear water drains on Coupe and Cabriolet

1437

55 62 19 Removing 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 as of MY 2003

1438

einordnung

USA and Canada vehicles only No. 1 Designation Qty. Luggage 1 compartment lining Emergency release gripper 1 Removal Undo luggage compartment lining partly. Installation Install luggage compartment lining. Clip the gripper 2 into the luggage compartment lining 1 . Plug in electrical plug connection 3 . => Checking inner release of luggage compartment 1439

Unclip the gripper 2 from the luggage compartment lining 1 . To do so, press in the locking tabs arrows .

Electrical plug connection

Disconnect electrical plug connection 3 .

55 62 19 Removing and installing front emergency release as of MY 2003

einordnung (Trunk Entrapment)

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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 lid will open completely after 30 seconds. The luggage compartment 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 the lower part of the lock.

1. Engage the upper part of the lock 996 551 051 02 = tool (Porsche spare part) in the lower part of the lock direction of arrow . 2. Unlock unlocking lever in the luggage compartment. Check whether the upper part of the lid lock disengages automatically.

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Checking inner release of luggage compartment (Trunk Entrapment)

1440

55 84 19 Removing and installing engine cover release

Checking inner release of luggage compartment (Trunk Entrapment) Removing engine cover release Installing engine cover release top of page

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 lid will open completely after 30 seconds. The luggage compartment 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 the lower part of the lock.

1. Engage the upper part of lid lock, Part No. 996 551 051 02 = tool (Porsche spare part), in the lower part of the lock direction of arrow . 2. Unlock unlocking lever in the luggage compartment. Check whether the upper part of the lid lock disengages automatically. top of page

Removing engine cover release

Remove front bumper 6, 631019 Removing and installing front bumper .

55 84 19 Removing and installing engine cover release

1441

einordnung

1. Unscrew both fastening screws and remove the retaining strip.

2. Disconnect the electrical plug connection. 3. Unscrew the fastening screws and disengage 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 the motor on the retaining strip and screw tight with the fastening nuts. Tightening torque 9.7 Nm (7 ftlb.).

Removing engine cover release

1442

einordnung Install front bumper 6, 631019 Removing and installing front bumper .

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Installing engine cover release

1443

57 51 16 Setting the door

57 51 16 Setting the door

1444

einordnung

No. Procedure Instructions 1 Setting the door Undo fastening screw 1 . Set the contour in relation to the wing and the side at front member by shifting the angle pieces 3 in their vertical and horizontal positions. 5 Body gap dimensions The setting range can be extended by removing the centring sleeve 2 . 2 Setting the door Undo fastening screw 4 . Set the contour in relation to the rear wing and the at rear side member by shifting the latch striker 5 in its vertical and horizontal position. 5 Body gap dimensions

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

57 51 16 Setting the door

1445

57 51 19 Removing and installing door

57 51 19 Removing and installing door

1446

einordnung

WARNING Danger of injury if side airbag units in the door are triggered while ignition key is not removed Always remove ignition key during body work, and do not commence adjustment work until a waiting period of at least 1 minute has elapsed! When working on the airbag system and during straightening work in the context of body repairs, the ground strap must be disconnected!

No. 1

Procedure Instructions Disconnecting the electrical Loosen Torx screw (T20), push plug up by approx. 3 mm and plug connection then pull the whole plug connection out of the Apillar. Attention: locking tabs in the plug may break off! Pull out locking element at the bottom part of the plug connection and disconnect the plug connection. Releasing door brake Unscrew Torx screw on the door brake. 1447

57 51 19 Removing and installing door

einordnung 3 Undoing locking screw as of model year 2001 Undoing locking screw up to model year 2000 Insert special tool No.9666, 2.4 (angle screwdriver) into the upper door hinge and counter. Unscrew locking screw from the lower door hinge and lift the door upwards out of the hinges. Unscrew locking screw from the door hinge and lift the door upwards out of the hinges.

No. Procedure 1 Engaging the door up to model year 2000 2

Instructions Engage the door in the door hinge from above and screw in the locking screw. Note: the locking screw is microencapsulated and must be replaced every time it is unscrewed. Tightening torque 10 Nm (7.5 ftlb.) Engaging the door Engage door in door hinge from above, screw in locking screw and tighten as of model year with 13 Nm (9.5 ftlb.) . 2001 Note: the locking screw is microencapsulated and must be replaced every time it is unscrewed. 1448

57 51 19 Removing and installing door

einordnung Use special tool No. 9666, 2.4 (angle screwdriver) to counter. Fitting door brake Screw the door brake to the body with the fastening screw. Tightening torque: 23 Nm (17 ftlb.) Connecting Connect electrical plug connection. electrical plug Attention: locking tabs in the plug can break off! connection Press in the securing latch of the plug connection B . Push the whole plug connection into the Apillar. Press the plug down approx. 3 mm, so that the locking tab C engages in the retaining bracket. Then screw the Torx fastening screw (T20) tight. Tightening torque: 2.5 Nm (2.0 ftlb.)

3 4

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

57 51 19 Removing and installing door

1449

57 51 37 Disassembling and assembling door

Disassembling door Assembling door

top of page

Disassembling door
WARNING Danger of injury if side airbag units in the door are triggered 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 the battery must be disconnected during work on the airbag system and alignment bench work within the framework of body repair! 57 51 37 Disassembling and assembling door 1450

einordnung CAUTION Damage to the bowden cable when removing door trim panel! Damage by bending the bowden cable at the hook! Pull the hook out of the end piece only after installation in the inner door release! CAUTION Damage to plug connection lugs during door removal! Damage to lugs when pulling the plug connection out of the Apillar! The locking element at the bottom part of 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 lock should be installed only when the actuating lever is in basic position! Note The door trim parts must be removed before removing the parts inside the door! Follow the special instructions on installation and adjustment for assembly of the door: Serv. No. 70 39!

1. Remove mount Undo the M6 x16 hexagonhead bolt and remove the mount.

Disassembling door

1451

einordnung

2. Unclip and disengage the bowden cable a. Disengage support frame arrow D upwards. b. Unclip bowden cable arrow B from the door lock. c. Swivel bowden cable by 90 arrow B and pull it out of the actuating lever arrow A .

3. Disconnect 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 nuts M6. h. Separate bottom part of door handle from door handle and remove. i. Press electrical plug connection off microswitch A and disconnect. j. Unclip on the base of the electrical lead B . Disassembling door 1452

einordnung

5. Remove door lock k. Undo microencapsulated Torx screws T40 M8 x 14. l. Disconnect the electrical plug connection. To do this, press the locking lug A on the plug connection and separate in the direction of the arrow 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. Remove power window unit p. Disconnect the electrical plug connection. q. Undo collar nuts M6 from the power window unit. r. Pull the power window unit downward out of the door opening.

Disassembling door

1453

einordnung

8. Remove door brake s. Unscrew Torx screw M8 A from the Apillar. t. Remove collar nuts from the door brake. u. Pull out the door brake towards the inside. v. Remove 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 window guide rail z. Unscrew the B3.5 x 9.5 sheetmetal screw from the window guide rail. aa. Pull off the B 3.5 sheetmetal nut.

Disassembling door

1454

einordnung

11. Remove door channel seal on inside Pull the door channel seal on the inside off the bead of the door channel.

12. Remove lid Press out the 24 x 40 lid A 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. Remove angle piece Unscrew T 45 M8 x 33 Torx screw from the angle piece and the 12 x 8 x 7 centring sleeve. top of page Disassembling door 1455

einordnung

Assembling door
WARNING Danger of injury if side airbag units in the door are triggered 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 the battery must be disconnected during work on the airbag system and 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 achieve better adhesion, heat the insulation using a hotair gun! Peel off the backing and stick the insulation into the door below the sideimpact bar.

2. Fit angle piece Position the angle piece with the 12 x 8 x 7 centring sleeve on the door and fasten with the T 45 M8 x 33 Torx screw. Tightening torque: 23 Nm (17 ftlb.)

Assembling door

1456

einordnung

3. Fit wiring harness a. Insert wiring harness into the door in the direction of the arrow . b. Clip in 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 bead of the door channel and press it on.

6. Fit window guide rail Assembling door 1457

einordnung c. Push on the B 3.5 sheetmetal nut. d. Position the window guide rail and fasten it with the B3.5 x 9.5 sheetmetal screw. Tightening torque: 1.4 Nm (1 ftlb.)

7. Fit door seal on outside Position door seal on the outside at 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 brake from the inside and fasten it with the collar nuts. Tightening torque: 10 Nm (7.5 ftlb.) i. Screw Torx screw M8 A onto the Apillar. Tightening torque: 23 Nm (17 ftlb.)

9. Fit power window unit Assembling door 1458

einordnung j. Insert power window unit into the door opening from below. k. Fasten the power window unit with the M6 collar nuts. Tightening torque: 10 Nm (7.5 ftlb.) See: Additional adjustment instructions for the power window. l. Plug in the electrical plug connection.

10. Fit door window m. Insert door window into the door channel and position it in the front and rear clamping pieces of the power 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 torque: 8.5 1.5 Nm (6.0 1.0 ftlb.)

11. Fit door lock Note The actuating lever must be locked in basic position before installation! Observe additional instructions for adjusting the door lock! o. Insert door lock with actuating motor unit into the door and fasten with the microencapsulated T40 M8 x 14 Torx screw. Tightening torque: 20 +2 Nm (15 + 1.5 ftlb.) Assembling door 1459

einordnung p. Plug in the electrical plug connection.

12. Fit connection piece q. Clip in the electrical lead B on the base. r. Insert door handle and position the bottom part of the door handle on the door handle from inside. Tighten with the collar nuts M 6. Tightening torque: 10 Nm (7.5 ftlb.) s. Connect electrical plug connection 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 handle arrow C to ensure that the handle and door lock function without play.

14. Fit bowden cable w. Insert bowden cable into the actuating lever arrow D and rotate by 90 arrow C . x. Clip bowden cable into the door lock arrow B . y. Engage support frame arrow A on the door lock. Assembling door 1460

einordnung

15. Fit mount Position the mount in the door and fasten it with the M6 x 16 hexagonhead bolt. Tightening torque: 10 Nm (7.5 ftlb.)

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Assembling door

1461

57 51 37 Disassembling and assembling door

Diagram: sheetmetal clips and grommets Basic setting of door lock Standardising the system Fitting the door window 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 and sides Adjusting the lower stop of the power window unit top of page

Diagram: sheetmetal clips and grommets

57 51 37 Disassembling and assembling door

1462

einordnung

A Grommet B M6 sheetmetal clip C M5 sheetmetal 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! Diagram: sheetmetal clips and grommets 1463

einordnung 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 the battery must be disconnected during work on the airbag system and alignment bench work within the framework of body repair!

Basic setting of the door lock before installation

CAUTION To prevent locking or unlocking actuation, or incorrect installation of the door lock! 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 simultaneously lower the spring hook of the actuating lever until it engages in the locking spring B . Note Greater force is necessary to actuate the door handle after installation of the door lock as the locking spring audibly disengages. Note Make sure that the lugs of the support frame are correctly locked when assembling the door lock to protect againt theft arrows: D .

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Basic setting of door lock

1464

einordnung

Standardising the system

Standardising the power windows

The system must be restandardised after an interruption in the power supply to the power window electronics in the door. The position values for the shortstroke lowering function, positioncontrolled lowering function in the case of convertible top actuation and enabling for "automatic startup of window closing" (onetouch function) are redefined. The standardisation process is initiated by continuous actuation of the operating button Raise window . Hold down the button Raise window until the window 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 motor is switched off after a delay of 500 ms.

Precondition for operation of the power windows

Ignition switched on. Ignition key should not be removed from the steering lock with the ignition switched off. The door is opened for the first time after switching off the ignition. Door opened.

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Fitting the door window in the clamping jaws

1. Insert the door window through the door channel into the clamping jaws of the front and rear drivers. 2. Position the door window corner flush with the driver at front. Standardising the system 1465

einordnung Note The bottom edge of the window must rest on the screw during adjustment. 3. Tighten the clamping jaws after completing the adjustment. Tightening torque: 8.5 Nm (6 ftlb.) top of page

Adjusting the door window angle in the vehicle's longitudinal direction

Driver 1. Adjust to equalise the angle of the door window 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 the upper limit stops of the drivers by screwing the Torx screw T30 in or out with socket E6 in or against the direction of travel. Adjustment range approx. 15 mm 2. Adjust the drivers so that they meet the upper limit stops at the same time. Note

Fitting the door window in the clamping jaws

1466

einordnung The adjusting screws of the drivers for the upper limit stops for the door window height are accessible through 2 holes at the bottom of the door.

Adjustment procedure:
1. Open the doors 2. Lock door lock with a screwdriver. 3. Move the power window regulator into its upper position. 4. Adjust door window height at the drivers so that 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 until the window lowering function is activated. Adjustment valve for window lowering function approx. 13 mm Note The wax marking along the door window should be uniformly approx. 4 mm.

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Adjustment of the door window pressing force on the door seal at the top and sides

Adjusting the door window height

1467

einordnung

1. Move the power window unit rails by approx. 10 mm outwards or inwards. Note The adjusting nuts of the power window unit rails for the pressing force of the door window upper edge against the convertible top are accessible through two holes at the bottom of the door.

Adjustment procedure:
1. Open the doors. 2. Move the power window regulator into its 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 the side Tightening torque: 10 Nm (7.5 ftlb.)

Checking the adjustment:

Clamp a sheet of paper between the door window and door seal. Note It must not be possible to pull out the sheet of paper.

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Adjusting the lower stop of the power window unit

Adjustment of the door window pressing force on the door sealat the top and sides

1468

einordnung

Note When replacing the power window unit, make sure that the correct position of the lower limit stop is selected for the respective model. There are two bores lying one above the other with the screwedon limit stops in the front power window unit rail. The upper limit stop must be removed for the 911 Carrera (996) model.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Adjusting the lower stop of the power window unit

1469

64 12 19 Removing and installing windscreen

Removing windscreen Preparing the window section for installation Preparing the windscreen for installation Fitting windscreen Overview of tools and materials

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Removing windscreen
WARNING Danger of cut injuries when removing and installing car windows!

64 12 19 Removing and installing windscreen

1470

einordnung Cutting out glued car windows may lead to cut injuries to the skin and the eyes due to flying glass splinters and 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 with the power supply disconnected in order to ensure that the cutter cannot be switched on accidentally. 1. Removing cowl panel cover 702219 Removing and installing cowl panel cover 2. Removing inner Apillar trim 705719 Removing and installing trim of A, B and Cpillars 3. Removing interior rearview mirror 682719 Removing and installing interior rearview mirror 4. Opening door windows Lower the door windows. Note The door windows must not be closed until after the curing time has elapsed.

5. Pulling off cover section Undo and remove the cover section 1 .

6. Removing defroster covers Lift the alarm readiness light 2 and unclip it to the rear. Lift the defroster covers on the left and right 3 and 4 and unclip them. Check fastening clips 5 , replace if necessary.

Removing windscreen

1471

einordnung

7. Disconnecting windscreen antenna plug connection Release windscreen antenna plug connection arrows and pull it off.

8. Removing spacer blocks Insert a spatula under the spacer 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 described in => Removing glass with cutting wire separator.

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Preparing the window section for installation

Preparing the window section for installation

1472

einordnung

1. Removing adhesive from the body When removing remaining adhesive 7 with the cutting tool C and the flashing knife D on the body, ensure that a surface coating of adhesive remains 8 . Note The surface coating of adhesive residue helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution.

2. Cleaning and priming paint damage or newly builtup paint areas in the window aperture of the body Clean new paint areas or damage to the top coat paint in the nonvisible area of the glass section in the body with cleaning solution H1 and patch with primer H2 . Note A ventilation period of at least 10 minutes must be observed between the cleaning of the glass section and the application of the primer! No cleaning solution residues may remain on the body.

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Preparing the windscreen for installation

Preparing the windscreen for installation

1473

einordnung

1. Removing adhesive from the windscreen Note Only if the windscreen is reinstalled! Equip cutting device C with the flashing knife D and remove the remaining adhesive from the windscreen, ensuring that a surface coating of adhesive 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. Fitting surrounding section and cover section Place surrounding section 9 on the windscreen and press cover section 1 into the groove of the surrounding section. Note If the surrounding section and cover section were removed from the rear window undamaged, they can be reused.

Preparing the windscreen for installation

1474

einordnung 3. Marking the bonding area Note Only if the windscreen is new and does not have a preliminary coat! Before applying the adhesive material, mark the course of the adhesive bead in accordance with the dimensions E = 160 mm, F = 30 mm on the left and right on the lower edge of the windscreen.

4. Activating the bonding section of the windscreen Note Only if the windscreen is reinstalled! During long idle 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 ventilation period of at least 10 minutes must be observed between the cleaning of the glass and the application of the primer! No cleaning solution residues may remain on the body.

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Fitting windscreen
CAUTION Danger of material damage if specified curing time of adhesive is not observed! The vehicle must not be used until the curing time has elapsed. Fitting windscreen 1475

einordnung 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 10C Fixing time: approx. 1 hour Note The removed windscreen can be reinstalled if there was no prior damage to the windscreen and the windscreen was removed without damage. 1. Fitting spacer blocks Clip in spacer blocks and press in bodybound rivets.

2. Fitting defroster covers and the alarm readiness 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 2component bonding material for processing => Processing of Porsche 2component window bonding agents Note The bonding material has an open time of 15 min , which means that the bonding material must be applied and 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 processing.

Fitting windscreen

1476

einordnung

4. Applying bonding material to the windscreen Apply 2component bonding material with the adhesive gun A to the windscreen along the cover section as a triangular bead measuring X = approx. 15 mm . Note When applying the adhesive, it is essential to ensure that the adhesive bead overlaps by approx. 30 mm at the beginning and at the end.

5. 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 windscreen up as far as it will go. When doing so, press the lower edge of the glass against the spacer blocks. 6. Cleaning fields of vision Adhesive which has oozed out must be removed immediately and the affected fields of vision must be cleaned using cleaning agent H1 .

7. Attaching windscreen antenna Fitting windscreen 1477

einordnung Insert the plug of the windscreen antenna into the antenna amplifier. 8. Installing inner Apillar trim 705719 Removing and installing trim of A, B and Cpillars 9. Installing cowl panel cover 702219 Removing and installing cowl panel cover 10. Bonding on interior rearview mirror Note Only with new windscreens! 682713 Bonding on 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 three hours! 12. Closing door windows Note The door windows must not be closed until after the curing time has elapsed.

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Overview of tools and materials

The following tools and materials are required for removing and installing the windscreen with 2component adhesive:

Overview of tools and materials

1478

einordnung

Item A B C D H

Designation Double cartridge gun VAS 5237 Pipette VAG 1344 Special electric cutter (fine) VAG 1561 A Flashing knife, Utype 639.031.130.22 2component window bonding agent 000.043.300.94

Source Remarks See Workshop Equipment Manual, Chapter 3.5 See Workshop Equipment Manual, Chapter 3.5 See Workshop Equipment Manual, Chapter 3.5 Contains set components H1H8

Item H1 H2 H3 H4

Designation Cleaning solution Primer Activator Swab

Item H5 H6 H7 H8

Designation Cartridge, component A Cartridge, component B Mixing nozzle Processing nozzle 1479

Overview of tools and materials

einordnung

Item A

Designation Source Glass separating tool VAG 1474 See Workshop Equipment Manual, B Chapter 3.5 Cutting thread See Parts Catalogue in Main Group 8

Remarks Contains set components A1A9

Item A1 A2 A3 A4 A5

Designation Guide rails Cutting tool (wire holder) Spooling device Awl Guide rails

Item A6 A7 A8 A9

Designation Filler Steering roller with arm bracket Handle Square cutting wire

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Overview of tools and materials

1480

64 54 19 Removing and installing power window motor

Removing power window motor Installing power window motor Standardising the new power window motor Tightening torques top of page

Removing power window motor

1. Close door window. WARNING Airbag could inflate. Possible danger of injury or damage during fitting. 1. Remove ignition key. 2. Disconnect and cover the negative terminal of the battery. 3. After the battery is disconnected, work on the vehicle may only be started after a waiting period of 1 minute. 2. Remove door panel and loudspeaker unit. Carefully remove (do not crack) the front moulded foam part from the inside of the door near the power window motor and the loudspeaker cutout. See also: 705919 Removing and installing door trim panel.

3. Loosen the three fastening nuts arrows from the power window motor. 4. Press the power window unit out of the inner door panel until the fastening pins are free. 5. Unlock and remove the electrical plug connection arrow on both sides. 6. Unscrew fastening pins of power window motor. Remove power window unit from the toothing and take out through the loudspeaker cutout. top of page

Installing power window motor

1. Guide power window motor through the loudspeaker cutout and insert in the toothing. Tighten fastening pins of power window motor. => Tightening torques 2. Engage electrical plug connection. 3. Push power window unit onto fastening pins. 64 54 19 Removing and installing power window motor 1481

einordnung 4. Tighten the three fastening nuts on the power window motor. => Tightening torques 5. Carefully glue the moulded foam part onto the inside of the door (protects against water leaking in). 6. Install loudspeaker unit and door panel. 7. Connect the battery. top of page

Standardising the new power window motor

1. Switch on ignition. 2. Open door window completely 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 power window motor. Standardisation is then completed. 3. Perform a function test. top of page

Tightening torques

Location Fastening pins M6 Fastening nut M6

Illustration

Thread M6 M6

Tightening torque [Nm] (ftlb.) 10 (7.5) 10 (7.5)

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996430, 996431, 996630, 996631

Installing power window motor

1482

64 71 19 Removing and installing rear power windows (Cabriolet)

Removing rear power 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

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64 71 19 Removing and installing rear power windows (Cabriolet)

1483

einordnung

Removing rear power windows (Cabriolet)

No.

1 2

Procedure Instructions Convertible top in service Removing and installing convertible top, 610119 position Note: Removal and installation of the rear power window should be carried out with a rear window pane. Otherwise adjustment work is hindered during installation. Removing sidepanel Removing sidepanel lining 1 . 70 75 19 lining Removing rear side Undo front and rear fastening screws 2 from the window inner seal convertibletop support and the belt guide section, and pull rear side window inner seal 3 up and out.

Removing rear power windows (Cabriolet)

1484

einordnung 3 4 Press the microswitch 4 in the windscreen frame and actuate the rocker switch 5 at the same time. Releasing power window Release adjusting elements with the adjustment tool 7 . To do this, loosen and unscrew the nuts 6 from the adjusting element. Adjustment tool for the rear power window. => Tools and materials Closing side window

CAUTION Damage to or destruction of the convertible top when the convertibletop support is removed! The convertible top must no longer be electrically operated when the convertibletop support is detached.

No. Procedure 5 Detaching convertibletop support

Removing power window

Instructions Undo fastening screws 2 and fastening nuts 8 from the convertibletop support 10 , pull the deflection fitting and belt guide section 9 up and out. Pull convertibletop support 10 inward and fix between Bpillar and the convertibletop support with a spacing block 12 dimension A = 30 mm . Push rear power window 11 upward, push both locking tabs of the electrical connection 13 outward and disconnect.

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Installing rear power windows (Cabriolet)

Installing rear power windows (Cabriolet)

1485

einordnung

No. Procedure 1 Inserting power window 2 Screwing down convertibletop support

3,4 Adjusting and screwing down power window

Instructions Connect electrical plug connections 13 , insert power window 11 into the window shaft from above and position in the mounts in the inner side section. Remove spacing block 12 between Bpillar and convertibletop support 10 . Position fastening screws 2 and fastening nuts 8 in the convertibletop 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.) By moving the power window 4 with respect to the longitudinal axis of the vehicle, the power window can be adjusted by dimension Y = 10 mm . The contact pressure of the side window upper edge on the convertibletop is adjusted by screwing the adjusting element A in or out by dimension X = 1486

Installing rear power windows (Cabriolet)

einordnung 10 mm . The contact pressure on the rear window inner seal or the offset from the door window is adjusted by screwing both of the upper adjusting elements B in or out by dimension X = 5 mm . Adjustment tool for the rear power window. => Tools and materials Step 1: Figure 3 Adjust the basic setting of the adjusting elements B from the top edge of the rear side section to the side window. Dimension C Front top edge of rear side section = 11 mm Dimension D Rear top edge of rear side section = 14 mm Step 2: Figure 3 Push the power window backward or forward to adjust the gap E = 9 mm between the side window and door window. Step 3: Figure 4 Adjust the contour or the offset from the door window on adjusting element A . Screw down adjusting elements A and B . Tightening torque 23 Nm (17 ftlb.) Installing rear side Insert rear side window inner seal 3 into rear side section slot and position window inner seal on the convertibletop support or belt guide section. Screw in fastening screws 2 and tighten. Installing 70 75 19 sidepanel lining

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Additional instructions for adjusting or replacing the rear power window

1. The rear power windows can be operated if: the convertibletop 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 is opened for the first time. the door is open, USA vehicles do not have this function. 1. Standardising the system The system must be restandardised after an interruption in the power supply to the power window electronics. To do this the convertible top must be closed. The positioncontrolled lowering function in the case of convertible top actuation, and enabling for "automatic startup" of window closing and opening are redefined. The standardisation process is initiated by continuous actuation of the operating button toward "close window". To do this the convertible top must be closed and the hardtop must be fitted. The button must be held until the window is closed and is switched off by the blockage detection function of the power windows. 2. Blockage detection function If the window drive encounters resistance when activated, the motor is switched off after a delay of 500 ms. If the rocker switch is pressed again within 10 seconds, the side window closes the power window with all of its closing force. The anticrushing protection is deactivated. top of page Additional instructions for adjusting or replacing the rear power window 1487

einordnung

Tools and materials

Item 1

Special tool designation Adjustment tool 1231

Remarks Gr. 2.4; Workshop Equipment Manual

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Tightening torques

Location Illustration Thread Fastening screws and fastening nuts in convertibletop 2.8 M8 support Fastening screw for tightening the deflection fitting in M8 the belt guide section. Adjusting elements of the door window A, B

Tightening torque [Nm] (ftlb.) 23 (17) 50 (37) 23 (17)

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Test and adjusting values

Designation Adjust power windows

Dimension C D E

11 mm 14 mm 9 mm

Note Front top edge of rear side section Rear top edge of rear side section Gap between side window and door window

996630, 996631, 996620, 996621, 996650, 996651

Tools and materials

1488

64 75 19 Removing and installing side window

Removing side window Installing side window Test and adjusting values Tightening torques

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Removing side window

64 75 19 Removing and installing side window

1489

einordnung

No. Procedure Removing B and C pillars 1 2 3

Instructions 705719 Removing and installing trim of A, B and C pillars. Unscrew fastening nuts and screws. Unscrew the fastening screw1 and remove the washer 2 . Unscrew fastening nuts 3 . Remove side window. Pull out side windows 4 downward in in direction of arrow . Pull off the rubber seal Pull off rubber seal5 from the rim of the side window section. Removing the side window seal and => Removing side window seal retaining strip, see:

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Removing side window

1490

einordnung

Installing side window

Note The removed side window can be reinstalled if: there is no prior damage to the side window. the side window was removed without being damaged.

No. 1

Procedure Fitting the rubber seal

Instructions Fit the rubber seal5 on the rim of the side window section.

Installing side window

1491

einordnung 2 Remove side window. Affix suction cups to the side window. Insert side window 4 at the top in the direction of arrow . 1 Keep pressing the side window4 upwards in direction of arrow B and insert at the bottom. 2 Pull the lip of the seal forward under the side window 4 using a plastic spatula. 3 Keep pressing the side window4 upwards in direction of arrow B and insert the spacer in the retaining rail. => Test and adjusting values Screw down the fastening screw 1 and washer 2 . Screw down the fastening nuts 3 . Tightening torque: => Tightening torques 705719 Install trim of A, B and Cpillars.

3 4

Adjusting gap dimension Unscrew fastening nuts and screws. Install B and C pillars

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Test and adjusting values

Designation Door window to side window

Dimension 3 7 1mm

Note Door window lowered, max. 1 mm

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Tightening torques

Location Fastening screw body to side window Fastening nuts to side window adjusting element

Illustration 1 2

Thread M6 M8

Tightening torque 10 Nm (ftlb.) 17 Nm (ftlb.)

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Test and adjusting values

1492

64 75 19 Removing and installing rear side window (Cabriolet)

Removing side window Installing side window Tightening torques Test and adjusting values top of page

Removing side window

Release the side window from the clamping jaws of the rear power window with the sidepanel lining and rear side window inner seal removed and the side window extended. To do this press the microswitch in the windscreen frame and actuate the rocker switch at the same time until the side window is completely extended. => Removing rear power windows (Cabriolet) Lift the side window upward out of the rear side section slot. top 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 side window through the side section slot into the clamping jaws arrows of the front and rear drivers.

2. Adjusting the side window angle in the vehicle's longitudinal direction Moving the side window into the clamping jaws inset on the receiving rollers equalizes the angle of the side window to the door window. The window bottom edge must lie against the receiving rollers in the clamping jaws. Adjust the side window according to the contour of the door window and the gap E = 9 mm . Tighten the clamping jaws after completing the adjustment. 64 75 19 Removing and installing rear side window (Cabriolet) 1493

einordnung Tightening torque: 8.5 (6.5) 1.5 Nm (1 ftlb.)

3. Adjusting the lower stop of the power window unit It is possible to adjust the height of both lower stops arrows . However, this should only be adjusted synchronously. The adjustment is only possible when the side window is lowered. top of page

Tightening torques

Location Clamping jaws for installing the side windows

Illustration

Thread

Tightening torque [Nm] (ftlb.) 8.5 (6.5) 1.5 (1)

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Test and adjusting values

Designation Dimension Note Gap for adjusting the side E 9 Adjust the side window according to the contour of the window mm door window and the gap.

996620, 996621, 996650, 996651, 996630, 996631

Installing side window

1494

64 76 19 Removing and installing side window seal

Removing side window seal Installing side window seal Materials and tools

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Removing side window seal

64 76 19 Removing and installing side window seal

1495

einordnung

No.

Procedure Removing side window Removing side window seal Boring out side window seal Removing the retaining strip

Instructions => Removing side window Bore out pop rivet from the integrated sheet metal strip 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 strip2 . Bore out the pop rivets3 from the side window seal 1 using a 4.1 mm drill bit. => Removing the retaining strip

Removing side window seal

1496

einordnung

Removing the 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

Removing the retaining strip

1497

einordnung

No. Procedure Installing the retaining strip 1 Riveting down the side window seal to the body 2 3 Positioning the side window seal in the retaining strip Fitting the side window seal in the retaining strip

Riveting down the side window seal Installing side window

Instructions => Installing the retaining strip Position the side window seal 1 on the centering holeA and rivet it down using the pop rivet 3 . Then rivet down all pop rivets. Coat the retaining strip 2 with soapy water. Insert the side window seal 1 in the retaining strip 2 . Starting from the rear, fit the side window seal 1 in the direction of arrow in the retaining strip 2 using the fitting roller. => Materials and tools Position the integrated sheet metal strip of the side window seal 1 on the body and rivet it down using the pop rivet 3 . => Installing side window

Installing side window seal

1498

einordnung

Installing the retaining strip

Installing the retaining strip Position the retaining strip 2 on the centering hole C and rivet the retaining strip down using the pop rivet 3 . When riveting down 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 1

Special tool designation Fitting roller 1631 For fitting in the side window seal

Remarks Commercially available tool Gr. 2.4; Workshop Equipment Manual

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Installing the retaining strip

1499

64 76 19 Removing and installing rear side window seal (Cabriolet)

Removing side window seal Installing side window seal top of page

Removing side window seal

Remove the side window seal with the convertible top open and the side window extended. To do this press the microswitch in the windscreen frame and actuate the rocker switch at the same time until the side window is completely extended. => Removing 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 present. Pull the side window seal from below into the window profile. Pull it in using soapy water as a lubricant. Clean the upper seal end (free from grease and lubricant). Coat the upper surface of the seal 1 with Loctite 480 instant adhesive, and bond with the profile of the side window.

996620, 996621, 996650, 996651, 996630, 996631

64 76 19 Removing and installing rear side window seal (Cabriolet)

1500

64 86 19 Removing and installing rear glass window of Cabriolet

Removing rear glass window of Cabriolet Installing rear glass window of Cabriolet Tools and materials Shown on 911 Carrera (996)

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Removing rear glass window of Cabriolet

64 86 19 Removing and installing rear glass window of Cabriolet

1501

einordnung

Note The rear glass window can be fitted into the vehicle when the convertibletop covering is installed or removed. The rear glass window should always be installed first into the convertibletop covering when replacing the convertibletop covering.

No.

1 2

Procedure Removing roof lining at the front at rear Disconnecting the electrical plug connection

Instructions 708419 Removing and installing Cabriolet roof lining as of model year 2002 Disconnect electrical plug connection of the rear window heater 1, 2, 3 on the left and right.

Removing rear glass window of Cabriolet

1502

einordnung Detaching connection and tension strap 3 Removing metal clips Detach the connection to the convertibletop covering 6 . Detach the tension belt 4 from the frame of the rear window 5 . 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 . Remove the rear window 5 from the convertibletop covering 8 .

Taking off rear window

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Installing rear glass window of Cabriolet

CAUTION Installing rear glass window of Cabriolet 1503

einordnung Leak (entry of water) in rear glass window! The metal clips are designed to be fitted only once. Always replace the metal clips after removal 7 . Only fit the metal clips with the circlip pliers => Tools and materials.

No. Procedure 1 Positioning rear window and aluminium frame on the convertibletop covering

Instructions Note: Two persons are required for the work step. Position rear window 5 and aluminium frame 5a on convertibletop covering 8 . The aluminium frame and the rear window are initially held on the convertibletop covering with vicegrip wrenches on the left and right. => Tools and materials 1. Ensure that the markings C, D correspond at the top and bottom. 2. Check whether the edge frame 5c of the convertibletop covering is showing evenly all the way round and correct if necessary. Push new metal clips 7 into all sides of the frame cutouts F of the rear window. => Tools and materials => Use of the circlip pliers Push in the connection seal 10 of the roof lining 9 between the rear window and the frame. Ensure that the clearance cuts of the roof lining E on the left and right are positioned on the electrical connection of the rear window. Knock the metal clips 7 with a plastic hammer. Make sure that the metal clip 7 engages in the frame cutouts. Replacing convertibletop covering, 612855

Pushing the metal clips onto the aluminium frame

Installing rear roof lining

Installing metal clips Only when replacing convertibletop covering. Installing convertibletop covering Attaching connection and tension strap

Connecting electrical plug connection

Attach the tension strap 4 into the frame of the rear window. Lay the connection under the convertibletop strips X and above the corner bow Y . Observe sequence illustrated. Plug in electrical plug connection 1, 2, 3 . Check heating for rear windows. => Tools and materials 708419 Removing and installing Cabriolet roof lining as of model year 2002

Installing roof lining

top of page Installing rear glass window of Cabriolet 1504

einordnung

Tools and materials

Item 1 2

Remarks Spare parts Gr. 8 11/10; Parts Catalogue Circlip pliers No. 9697 for installing metal clips Porsche special tool Gr. 2.2; Workshop Equipment Manual Temperature probe No. 164 for checking heating of rear Commercially available tools window Gr. 2.4; Workshop Equipment Manual Two universal vicegrip wrenches No. 1272 for holding the Commercially available tools rear window on the convertibletop covering Gr. 2.4; Workshop Equipment Manual

Special tool designation Metal clips set for installing rear window

Use of the circlip pliers

1. Inserting metal clips into the circlip pliers a. Unscrew the knurled screw 11 with the circlip pliers in the direction of the arrow . Insert metal clip 7 into the Uprofile of the lower jaw A in direction of arrow . Insert the upper claw X into the metal clip 7 in direction of arrow at the same time. b. Insert into the upper adjusting claw Y in the metal clip 7 in direction of arrow . Tighten knurled screw 11 .

Tools and materials

1505

einordnung

2. Pushing metal clips onto the aluminiuim frame. Removing circlip pliers from the metal clip Pushing the metal clips onto the aluminium frame. => Installing rear glass window of Cabriolet c. Unscrew 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 Uprofile of the lower jaw A . e. Pull the circlip pliers to the left in direction of arrow and remove from the metal clip 7 with the upper claw X .

996620, 996621, 996650, 996651, 996630, 996631

Use of the circlip pliers

1506

64 86 19 Removing and installing rear window (hardtop)

Removing rear window (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

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64 86 19 Removing and installing rear window (hardtop)

1507

einordnung

Removing rear window (hardtop)

WARNING Danger of cut injuries when removing and installing car windows! Cutting out glued car windows may lead to cut injuries to the skin and the eyes due to flying glass splinters and 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 with the power supply disconnected, in order to avoid the cutter being switched on accidentally. 1. Removing hardtop Unlock hardtop and take it off the car. 2. Positioning the hardtop Place outer side of the hardtop on the assembly fixture.

3. Removing centring peg Unscrew the fastening screw 1 from centring peg 2 on the left and right and remove centring peg 2 .

4. Unclipping hardtop locking element trim Unclip hardtop locking element trim 3 on the left and right.

Removing rear window (hardtop)

1508

einordnung

5. Unclipping interior trim parts Unclip interior trim parts 4 at the side, front and rear from the hardtop body 5 .

6. Disengaging roof liner at rear Pull the plastic rail 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 avoid damaging the electric cable when cutting out the rear window, affix the cable to the rear window with adhesive tape.

Removing rear window (hardtop)

1509

einordnung 8. Turning hardtop Place hardtop on the assembly fixture and lock with the latching levers and the locking lever at front.

9. Pulling off cover section Undo and remove the cover section 9 . Note If the cover section is removed undamaged, it can be reused.

10. Removing rear window Fit a Utype cutting knife E to 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 damage the rivet connections that are connecting the hardtop body parts. When cutting out the rear window, make sure to cut close to the rear window. 11. Taking off rear window top of page

Preparing the window section (hardtop) for installation

Preparing the window section (hardtop) for installation

1510

einordnung

1. Removing adhesive on the hardtop body When removing remaining adhesive 10 with the cutter C and the flashing knife D on the hardtop body, ensure that a surface coating of adhesive remains 11 . Note The surface coating of adhesive residue helps new adhesive to stick. Keep cut surfaces clean and free of grease and do not clean with cleaning solution. Remove remaining adhesive between the rivet connections as much as possible without damaging the rivet connections.

2. Cleaning and priming paint damage or newly builtup paint areas in the window aperture of the hardtop body Clean new paint areas or damage to the top coat paint in the nonvisible area of the glass section in the hardtop body with cleaning solution H1 and patch with primer H2 . Note A ventilation period of at least 10 minutes must be observed between the cleaning of the glass section and the application of the primer! No cleaning solution residues may remain on the body.

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Preparing the window section (hardtop) for installation

1511

einordnung

Preparing the rear window (hardtop) for installation.

1. Removing adhesive from the rear window Note Only if the rear window is reinstalled! Equip cutter C with the flashing knife D and remove remaining adhesive from the rear window, ensuring that a surface coating of adhesive 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 the rear window Note Only if the rear window is reinstalled! During long idle periods apply activator H3 to the remaining adhesive. Note Only with new rear windows! a. Clean glass with cleaning solution H1 . Preparing the rear window (hardtop) for installation. 1512

einordnung b. Apply primer H2 to the glass flange in the area of the marking. Note A ventilation period of at least 10 minutes must be observed between the cleaning of the glass and the application of the primer! No cleaning solution residues may remain on the body.

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Installing rear window (hardtop)

CAUTION Danger of material damage if specified curing time of adhesive is not observed! The vehicle must not be used until 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 10C Fixing time: approx. 1 hour Note The removed rear window can be reinstalled if there was no prior damage to the rear window and the rear window was removed without damage.

1. Fitting cover section Attach cover section 9 to the rear window. Note If the cover section is removed from the rear window undamaged, it can be reused. 2. Preparing 2component bonding material for processing Installing rear window (hardtop) 1513

einordnung => Processing of Porsche 2component window bonding agents Note The bonding material has an open time of 15 min , which means that the bonding material must be applied and 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 processing.

3. Applying adhesive to the rear window Apply 2component bonding material with the adhesive gun A to the rear window along the cover section as a triangular bead measuring X = approx. 15 mm . Note When applying the adhesive, it is essential to ensure that the adhesive bead overlaps by approx. 30 mm at the beginning and at the end.

4. Inserting rear window into the hardtop body

Installing rear window (hardtop)

1514

einordnung Note Two persons are needed to insert and adjust the rear window. a. Attach suction cups B to the rear window. b. Insert the rear window at the top of the window aperture and lay it down carefully into the aperture.

5. Fixing rear window Press the rear window fully upwards, pressing on the lower edge of the glass while doing 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 of vision must be cleaned using cleaning agent H1 . 7. Turning hardtop Place outer side of the hardtop on the assembly fixture.

8. Plugging in rear window heater Connect electrical plug connection 8 to the left and right of the rear window.

9. Engaging roof liner to the rear

Installing rear window (hardtop)

1515

einordnung Engage roof liner 7 to the rear using plastic rail 6 .

10. Clipping in interior trim parts Clip in interior trim parts 4 at the side, front and rear on the hardtop body 5 .

11. Clipping in hardtop locking element trim Clip in hardtop locking element trim 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 hardtop on the car and lock it. top of page

Overview of tools and materials

The following tools and materials are required for removal and installation of the rear window with 2component adhesive:

Overview of tools and materials

1516

einordnung

Item A B C D E H

Designation Double cartridge gun VAS 5237 Pipette VAG 1344 Special electric cutter (fine) VAG 1561 A Flashing knife, Utype 639.031.130.22 Cutting knife, Utype 639.030.760.12 2component window bonding agent 000.043.300.94

Source Remarks See Workshop Equipment Manual, Chapter 3.5 See Workshop Equipment Manual, Chapter 3.5 See Workshop Equipment Manual, Chapter 3.5

Contains set components H1H8

Item H1 H2 H3 H4

Designation Cleaning solution Primer Activator Swab

Item H5 H6 H7 H8

Designation Cartridge, component A Cartridge, component B Mixing nozzle Processing nozzle

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Tightening torques

Location Centring peg fastening screw to hardtop body

Illustration Thread Tightening torque [Nm] (ftlb.) 1 M6 10 (7.5)

Tightening torques

1517

einordnung 996630, 996631, 996620, 996621, 996650, 996651

Tightening torques

1518

66 31 19 Removing and installing sill cover.

Removing sill cover Installing sill cover

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Removing sill cover

66 31 19 Removing and installing sill cover.

1519

einordnung

No. Procedure 1 Undoing front sill cover 2 3 4 Undoing rear sill cover Undoing sill cover on the lower side member Removing sill cover from the lower side member

Instructions Unscrew fastening screw 2 from the wheel housing liner 3 . Unscrew fastening screw 2 from the rear wheel housing liner 4 . Unscrew fastening screws 2 along the sill cover 1 . Remove sill cover from the lower side member in direction of arrow . Grommets 5 must always be replaced for installing the sill cover 1 .

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Removing sill cover

1520

einordnung

Installing sill cover

1 No. Procedure 1 Check Uclips and replace if necessary 2 Fitting grommets Instructions Check Uclips 6 and replace if necessary. The Uclips must be fixed firmly on the rim of the lower side member. All grommets 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 . Position sill cover 1 on the premounted grommets on the side member and tighten with fastening screws 2 . Tighten rear sill cover and the rear wheel housing liner 3 using the fastening screws 2 . 1521

3 4

Fitting sill cover Screwing on rear sill cover

Installing sill cover

einordnung 5 Screwing in front sill Tighten front sill cover and the front wheel housing liner 4 using the cover fastening screws 2 .

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Installing sill cover

1522

66 72 37 Disassembling and assembling pump unit

Removing hydraulic cylinder Filling the hydraulic cylinder Installing hydraulic cylinder Removing 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 rings should always be replaced when replacing the hydraulic cylinder or the pump drive.

66 72 37 Disassembling and assembling pump unit

1523

einordnung

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Removing hydraulic cylinder

Removing hydraulic cylinder

1524

einordnung

No. 1 2

Procedure Removing pump unit Pulling off cover caps Moving pump motor to initial position

Instructions 559037 Disassembling and assembling rear lid Pull off cover caps 7 from the hydraulic cylinders 2 . Before the pump unit can be disassembled, 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 to the polarisation arrangement A . The limit position is attained when the piston of the pump unit moves onto the mechanical stop or the amperage rating is larger than 10 A. => Tools and materials

CAUTION Removing hydraulic cylinder 1525

einordnung The drive module is pressurised! => Safety instructions for the pump unit hydraulic system of the rear spoiler

No. Procedure 3 Cutting tie wrap 4 Disconnecting hydraulic lines. Disconnecting hydraulic lines from the pump unit

Instructions Cut tie wrap on the hydraulic line 5 using a pair of side cutters. Unscrew the short banjo bolts 1 from the hydraulic cylinders 2 of the hydraulic lines 4, 5 . To do this, counter with an openended wrench C . => Removing pump

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Filling the hydraulic cylinder

1. Filling the hydraulic cylinder The hydraulic cylinder can only be filled in a retracted position. a. Assemble hydraulic cylinder 2 vertically and fill with 5 ml Pentosin perhydraulic cylinder using a syringe. => Tools and materials Only Pentosin CHF 11 S may be filled into the hydraulic cylinder. Quantity supplied 1 litre container => Tools and materials top of page

Installing hydraulic cylinder

Filling the hydraulic cylinder

1526

einordnung

No. Procedure Information:

1 2 3

Instructions The lines, banjo bolts and sealing rings included in the scope of replacement parts should always be replaced. Installing hydraulic line on the Observe installation sequence of the hydraulic lines! pump The hydraulic lines must be mounted first to the pump unit and the pump motor must be extended and retracted. => Installing pump Fitting short hydraulic line 4 . Fit short hydraulic line 4 with the sealing rings 6 . Screw in short banjo bolt 1 . Fitting long hydraulic line 5 . Fit long hydraulic line 5 with the sealing rings 6 . Screw in short banjo bolt 1 . Tightening short banjo bolt 1 Tighten short banjo bolt 1 , to do this, counter the hydraulic with tightening torque. cylinder 2 with an openended wrenchC . Tightening torque: 15 Nm (11 ftlb.)

Installing hydraulic cylinder

1527

einordnung 4 Fitting covering caps Bleeding the pump unit Push left and right covering cap 7 onto the hydraulic cylinder 2 . => Bleeding the pump unit

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Removing pump

No. Procedure Instructions Removing pump unit 559037 Disassembling and assembling rear lid Installing hydraulic => Installing hydraulic cylinder cylinder 1 Disconnecting pump Removing pump 1528

einordnung Unscrew the long banjo bolts 3 from the hydraulic lines 4, 5 . To do this, counter with an openended wrench C .

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Filling 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. Quantity supplied 1 litre container => Tools and materials top of page

Installing pump

Filling the pump unit

1529

einordnung

No. Procedure Information: 1 Fitting short hydraulic line Fitting long hydraulic line Affixing cable ties Pulling out pump unit

3 4

Instructions The lines, banjo bolts and sealing rings included in the scope of replacement parts should always be replaced. Lay short hydraulic line 4 to the left leading from the pump unit arrow A , position the sealing rings 6 . Screw in banjo bolt 3 and tighten slightly. Tightening torque: 1 Nm (0.5 ftlb.) Lay long hydraulic line 5 along the pump unit arrow B , position the sealing rings 6 . Screw in banjo bolt 3 and tighten slightly. Tightening torque: 1 Nm (0.5 ftlb.) Fasten long hydraulic line 5 to the pump unit with a cable tie arrow . 1. Pull pump unit out so far that oil (Pentosin) emerges from both lines 4, 5 . 2. 1530

Installing pump

einordnung To do this, connect wide contact to +12 V, narrow contact ground ( ) to the pump motor according to the polarisation arrangement B . 5 Inserting pump unit 3. Dip the hydraulic line ends completely in oil (Pentosin). 4. Insert pump unit to the 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 pointing vertically upward after removing from the oil bath.

Installing => Installing hydraulic cylinder or => Filling the hydraulic cylinder hydraulic cylinder

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Bleeding the pump unit

Bleeding the pump unit

1531

einordnung

No. 1

Procedure Pulling out pump

Bleeding short hydraulic line

Bleeding long hydraulic line

Instructions Pull hydraulic cylinder 2 out to the dimension Y = 35 +2 mm . To do this, connect 12 V to the pump. Observe polarisation arrangement A . Slowly tighten short hydraulic line 4 until the hydraulic cylinder 2 moves. If the hydraulic cylinder has reached the lower mechanical 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.) Slowly tighten long hydraulic line 5 until the hydraulic cylinder 2 moves. If the hydraulic cylinder has reached the lower mechanical stop inset X , push back onto the stop if necessary, hydraulic lines inset Z must be laid parallel to eachother. Tighten banjo bolt 3 . Tightening torque: 15 Nm (11 ftlb.) 1532

Bleeding the pump unit

einordnung Installing pump unit 559037 Disassembling and assembling rear lid

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Removing and installing wiring harness

Removing wiring harness

No. Procedure 1 Hydraulic cylinder, right 2

Instructions Loosen fastening screws on right hydraulic cylinder. Unscrew 2 fastening screws. 3. Screw can remain installed. Unscrew 4 fastening screws 2 from the holder 1 . 1533

Removing and installing wiring harness

einordnung Holder for micro switch. Remove additional brake light 3 Removing air guide 4 Removing fan with fan housing 6 Disconnecting mount 8 Electrical plug connection

3 4 5

Disengage cover A at the sides, unlock lock B . Pull off plug C and remove additional brake light 3 . Unscrew fastening screws 5 and remove air guide 4 . Disconnect plug connections for fan and engine compartment lighting on the fan housing. Unscrew fastening screws 7 and remove fan with fan housing 6 . Unscrew fastening screws 9 . Remove mount 8 . Pull off plug connection on the pump unit. Push in locking tab of the electrical plug connection C and pull apart. Cut cable tie on the pneumatic spring. Remove wiring harness.

6 7

Installing wiring harness

Removing wiring harness

1534

einordnung

No. Procedure 1 Fastening holder 1 for micro switch 2

4 5 6

Instructions Fasten holder 1 for both micro switches onto the hydraulic cylinder with the fastening screws 2 . Tightening torque: 0.5 Nm (0.5 ftlb.) Fitting pump unit plug connection Insert electric plug on the pump unit. and mount 8 . Screw in fastening screws 9 . Tightening torque: 10 Nm (7.5 ftlb.) Installing fan with fan housing Put on fan with fan housing 6 and tighten with the three 6 fastening screws 7 . Tightening torque: 10 Nm (7.5 ftlb.) Push on plug for fan and plug for engine compartment lighting. Installing air guide 4 Screw in both fastening screws 5 . Tightening torque: 10 Nm (7.5 ftlb.) Installing additional brake light Push on plug C . Insert brake light. Lock the lock B . 3 Engage cover C . Fastening right hydraulic cylinder 1535

Installing wiring harness

einordnung Screw the hydraulic cylinder to the spoiler with the fastening screws. Tightening torque: 10 Nm (7.5 ftlb.) Press plug connection together in direction of arrow until it engages. Lay electric line on the pneumatic spring and fix with tie wraps.

Connecting the plug connection

Removing and installing micro switches for rear spoiler

Note The rear 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 principle of the micro switches differs (NO or NC contacts)

Removing micro switches

1. Unscrew fastening screws 2 for holder, micro switch 1 on the right hydraulic cylinder (4 screws) and remove holder. 2. Press the micro switch carefully out of the bracket using a screwdriver.

3. Removing and installing micro switches for rear spoiler 1536

einordnung Open the protective sleeve of the wiring harness by a few centimetres and cut wiring of micro switch using a pair of side cutters.

Installing micro switches

1. Carefully push the new micro switch into the holder 1 . The micro switch with the blue lead at the bottom and the micro switch with the grey lead at the top. 2. The operating principle of the micro switches differs (NO or NC contacts) 3. Join wires using crimp connector and crimping tool. => Tools and materials Cut off lines to different lengths (due to the shrink connection). Slide shrinkfit hose over the leads. Strip 10 mm of insulation off the wires. Connect wires with crimp connectors (do not confuse colours of the individual wires). Shrink shrinkfit hoses with a hotair 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 with micro switch 1 on the hydraulic cylinder. Fastening screws 2 Tightening torque: 0.5 Nm.(0.5 ftlb.) top of page

Troubleshooting

1 2 3 4

Procedure Possible causes of fault

Work instruction Cause Diagnosis troubleshooting, spoiler drive Spoiler control, 9150 Drive motor for the pump does Connect battery voltage to the pump. Pump faulty, replace not turn. => Removing pump Drive motor for the pump turns. Pump faulty, replace Hydraulic cylinders do not move. => Removing pump One hydraulic cylinders does not Visual inspection: Hydraulic cylinder extend. oil loss, visible fluid (Pentosin) on faulty, replace hydraulic cylinder. => Removing hydraulic cylinder 1537

Removing micro switches

einordnung 5 Hydraulic cylinders do not extend. Visual inspection: oil loss, visible fluid (Pentosin) on the pump. Hydraulic cylinders extend automatically on parked vehicle. Pump faulty, replace => Removing pump Oil level too high. => Bleeding the pump unit

top of page

Tools and materials

Item 1

2 3 4

Designation of the special tool Pentosin CHF 11 S For filling the pump unit and the hydraulic cylinder Syringe Multimeter 155 Repair set for wiring harness 1551

Explanation Spare part Gr 4; Parts Catalogue

Commercial tool Workshop Equipment Manual, Gr. 2.4 Workshop Equipment Manual, Gr. 2.4

996420, 996421, 996450, 996451

Troubleshooting

1538

66 85 19 Removing and installing micro switches for rear spoiler

Note Remove micro switches Installing micro switches Tools Note The rear spoiler is controlled via the instrument cluster. The micro switches can be checked with the Porsche System Tester 2. The micro switches are located on the right hydraulic 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 cylinder (4 screws) and remove holder.

2. Press the micro switch carefully out of the bracket using a screwdriver. 3. Open the protective sleeve of the wiring harness by a few centimetres and cut wiring of micro switch using a pair of side cutters.

66 85 19 Removing and installing micro switches for rear spoiler

1539

einordnung top of page

Installing micro switches

1. Carefully push the new micro switch into the holder 1 . The micro switch with the blue lead at the top and the micro switch with the grey lead at the bottom. The operating principle of the micro switches differs (NO or NC contacts) 2. Join wires using crimp connector and crimping tool. => Tools Cut off lines to different lengths (due to the shrink connection). Slide shrinkfit hose over the leads. Strip 10 mm of insulation off the wires. Connect wires with crimp connectors (do not confuse colours of the individual wires). Shrink shrinkfit hoses with a hotair gun. It is essential that all wires are watertight. Wrap commercially available PVC tape all around the area of the connection points.

3. Position holder with micro switch 1 on the hydraulic cylinder. Fastening screws 2 Tightening torque: 0.5 Nm.(0.5 ftlb.) top of page

Tools

Item 1

Designation of the special tool Repair set for wiring harness 1551

Explanation Workshop Equipment Manual, Gr. 2.4

996420, 996421, 996450, 996451

Remove micro switches

1540

66 89 37 Disassembling 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 rearview mirror

1541

einordnung

No. Procedure Removing rearview mirror 1 Folding in the rearview mirror 2 Removing rearview mirror glass 3 Removing the rearview mirror shell 4 Removing the rearview mirror shell

Instructions

Fold in the rearview mirror in direction of arrow . Carefully pull the rearview mirror glass 2 out of the metal clips. Disconnect electrical plug connection 3 . Unscrew fastening screws 4 from the rearview mirror shell 1 . Remove rearview mirror shell 1 upwards in the direction of arrow . Remove foam strips.

Disassembling the rearview mirror

1542

einordnung

No. Procedure 5 Removing the cover 6 Removing the positioning motor 7 Removing the metal clip

Instructions Press lugs arrows of the cover 9 and remove. Unscrew fastening screw 6 from the positioning motor 7 . Disconnect electrical plug connection 8 . Unscrew fastening screw 10 from the metal clip 11 and the retaining bracket 12 .

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Assembling the rearview mirror

Assembling the rearview mirror

1543

einordnung

No. Procedure Instructions 1 Installing metal clips Position metal clip 11 on the retaining bracket 12 and tighten with the fastening screws 10 . 2 Installing positioning Plug in electrical plug connection 8 . motor Position the positioning motor 7 on the retaining bracket and screw down using the fastening screws 6 . 3 Installing cover Clip the cover 9 in the retaining bracket. Lug arrows must click into place.

Assembling the rearview mirror

1544

einordnung

No. Procedure 4 Connecting the rearview mirror shell 5 6 7 Tightening the rearview mirror shell Installing the rearview mirror glass Unfolding the rearview mirror Installing the rearview mirror

Instructions Stick the foam strips in die recess of the rearview mirror shell. Position the rearview mirror shell1 in the direction of the arrow on the retaining bracket. Secure the rearview mirror shell 1 with the fastening screws 4 . Plug in electrical plug connection 3 . Insert rearview mirror glass 2 into the metal clips. Fold up the rearview mirror in direction of arrow .

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Assembling the rearview mirror 1545

68 05 19 Removing and installing inner sill (driver's side)

Removing inner sill Installing inner sill

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Removing inner sill

68 05 19 Removing and installing inner sill (driver's side)

1546

einordnung

No. 1

Procedure Undoing hexagon socket head bolts 2 Removing the sill cover 1

Pulling off plug connections 5, 6 of the actuating switches

Instructions Remove plastic plugs 3 and undo the hexagon socket head bolts 2 from the sill by approx. 4 5 threads. Lift sill cover 1 upwards out of the bottom support with a plastic spatula and press out. Check fastening clips 4 , replace if necessary. Pull off plug connections 5, 6 on the actuating switches of the lids. Remove actuating switch if necessary. 5510 Dissassembling release for front lid 5557 Disassembling release for rear lid

top of page Removing inner sill 1547

einordnung

Installing inner sill

No. Procedure Instructions 1 Joining plug connections 5, 6 Install actuating switch if necessary. of the actuating switches 5510 Assembling release for front lid 5557 Assembling release for 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 engage. 3 Tightening hexagon socket head Screw in hexagon socket head bolts 2 of the sill by approx. 4 bolts 2 5 threads. Seal holes of the sill cover with plastic plugs 3 .

Installing inner sill

1548

einordnung 996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Installing inner sill

1549

68 05 19 Removing and installing inner sill (passenger's side)

Removing inner sill Installing inner sill

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Removing inner sill

68 05 19 Removing and installing inner sill (passenger's side)

1550

einordnung

No. Procedure 1 Undoing fastening screws 2 2 Removing sill 1

Instructions Lift rubber mat 2 upward out of the odmments tray and unscrew the fastening screws 3 from the sill. Lift sill 1 upwards out of the bottom support with a plastic spatula and press out. Check fastening clips 4 , replace if necessary.

top of page

Installing inner sill

Removing inner sill

1551

einordnung

No. Procedure 1 Putting on sill 1 2 Fastening sill 2

Instructions Clip in new fastening clips 4 if necessary. Insert sill 1 downward into the lower support and engage. Screw in fastening screws 3 and lay rubber mat 2 into the oddments tray.

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Installing inner sill

1552

68 11 19 Removing 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 compartment lock

1553

einordnung

No. Designation Qty. Removal Installation 1 Removing lid for 1 => Removing lid for glove => Installing lid for glove compartment glove compartment compartment 2 Fastening screws 2 Unscrew the fastening Screw in fastening screws 2 . screws 2 . Note: The lock for the glove compartment can not be removed from the handle. 3 Handle with lock 1 Remove lock for glove Position the lock for the glove for glove compartment 3 from the compartment 3 in the glove compartment glove compartment lid. compartment lid 1 and screw tight with the fastening screws 2 .

996430, 996431, 996630, 996631, 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651 Removing and installing glove compartment lock 1554

68 12 19 Removing and installing lid for glove compartment

Removing lid for glove compartment Installing lid for glove compartment Replacing microswitch and interior light Replacing pneumatic shock absorber

A = Lid for glove compartment B = Pneumatic shock absorber

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Removing lid for glove compartment

68 12 19 Removing and installing lid for glove compartment

1555

einordnung

No. 1 2

Procedure Unscrewing the front fastening screws Unscrewing fastening screws at the side

Instructions Unscrew front fastening screws 1 . Unscrew fastening screws 1 at the side.

top of page

Installing lid for glove compartment

Removing lid for glove compartment

1556

einordnung

No.

Procedure Checking rubber stop

1 2

Instructions Before installing the glove compartment lid, check the rubber stop 2 to the left and right and replace, if necessary. Screwing in the front fastening Screw in front fastening screws 1 . screws Screwing in fastening screws at Screw in fastening screws 1 at the side. the side

top of page

Replacing microswitch and interior light

Installing lid for glove compartment

1557

einordnung

1. Replacing microswitch and interior light Note In the case of a defective microswitch, the complete wiring harness 4 must be replaced! a. => Removing glove compartment b. On the retaining bracket 2 , press the locking tabs A apart. Guide out the microswitch 5 . c. Insert a plastic spatula into the side of the interior light 1 and press out. Disconnect 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 cutout of the glove compartment. e. Press the microswitch 5 into the retaining bracket 2 . Note the coding of the microswitch. f. To fit the glove compartment, engage the electrical lead 4 into the clip 3 . g. => Installing glove compartment top of page

Replacing pneumatic shock absorber

1. Removing the

Replacing microswitch and interior light

1558

einordnung pneumatic shock absorber Press the pneumatic shock absorber 1 out of the fastening tab arrow B . Turn the pneumatic shock absorber by 90 anticlockwise in the direction of arrow A and guide it 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 into the fastening tab towards the direction of arrow B .

996430, 996431, 996630, 996631, 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Replacing pneumatic shock absorber

1559

68 15 19 Removing and installing glove compartment

Removing glove compartment Installing glove compartment

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Removing glove compartment

68 15 19 Removing and installing glove compartment

1560

einordnung

No. Procedure 1 Unclipping plastic clips 2 3 4 5

Unscrewing the rear fastening screws Unscrewing the front fastening Unscrew fastening screws 4 from the glove compartment. screws Disconnecting the electrical plug Disconnect the electrical plug connection in the direction of connection the arrow . Removing the glove compartment Lift the glove compartment upwards arrow and guide it out of the dashboard 1 .

Instructions Unclip plastic clips 2 . Guide the insulation downwards out of both corners arrows . Unscrew fastening screws 3 from the glove compartment.

top of page

Removing glove compartment

1561

einordnung

Installing glove compartment

No. 1 2

Procedure Connecting electrical plug connection Installing glove compartment

3 4 5

Instructions Connect the electrical plug connection in the direction of the arrow . Swivel the glove compartment into the dashboard in the direction of the arrow . Note the position of the locating peg A . Screwing in the front fastening Screw in the fastening screws 4 in the glove compartment. screws Tightening torque: 2.5 Nm (2 ftlb.) Screwing in the rear fastening Screw in the fastening screws 3 in the glove compartment. screws Tightening torque: 2.5 Nm (2 ftlb.) Fitting the plastic clips 1562

Installing glove compartment

einordnung Position the insulation, making 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

Installing glove compartment

1563

68 17 19 Removing and installing center console (front section)

68 17 19 Removing and installing center console (front section)

1564

einordnung

No. Designation 1 Cover, front left

Qty. Removal 1 Unclip the front left cover 1 at the sides.

Cover, front right

3 4 5

Clip Cover cap (telephone trim panel) Fastening screw

10 1 9

Installation Position the front cover 1 on the front centre console 15 and clip it laterally into the clips 3 . Unclip the front right cover 2 at the Position the front cover sides. 2 on the front centre console 15 and clip it laterally into the clips 3 . Inspect clip 3 and replace if necessary.

68 17 19 Removing and installing center console (front section)

1565

einordnung 6 Telephone trim panel 1 Insert a wire into the hole of the cover cap 4 and pull off the cover cap to the rear. Undo the fastening screws 5 and lift the telephone trim panel off the front cover 8 . Insert the locking tabs of the telephone trim panel into the front cover 8 and screw it in place with the fastening screws 5 . Tightening torque: 2.3 Nm (1.5 ftlb.) Press in cover cap 4 .

7 8

Installation frame for (telephone handset) Cover, front left (telephone carrier)

1 1 Unscrew fastening screws 5 , unclip Position cover at the the cover from the centre console at the centre console at the side and remove to the rear. front, clip in at the side and fasten with the fastening screws 5 Tightening torque: 2.3 Nm (1.5 ftlb.) Unscrew fastening screws 5 and Position the adapter at the remove the adapter from the centre centre console at the front console at front. 9 and fasten with the fastening screws 5 . Tightening torque: 2.3 Nm (1.5 ftlb.) See: 911219 Removing and installing navigation unit CD drive See: 870219 Removing and installing the heating/airconditioning control Unclip the front trim 12 towards the Connect the electrical connection, position the front and disconnect the plug connection of the rocker switch for the front trim 12 on the centre console 15 and seat heating. press into place. Unclip the left cover 13 at the side Position the right cover and pull out to the rear. 13 on the centre console or on the cover panel of the support frame and clip the cover into the clips 3 at the side. Unclip the right cover 14 at the side Position the right cover and pull out to the rear. 14 on the centre console or on the cover panel of the support frame at the front and clip the cover into the clips 3 at the side. Undo fastening screws 5 and lift the Position the front of the front of the centre console 15 off. centre console 15 on the holder 18 or on the 1566

Adapter

10 Combisingle CD drive 1 for navigation 11 Heating/airconditioning 1 control 12 Front trim 1

13 Cover, left

14 Cover, right

15 Centre console (front section)

68 17 19 Removing and installing center console (front section)

einordnung dashboard frame and secure with the fastening screws 5 . Inspect and replace if necessary. Tightening torque: 10 Nm (7.5 ftlb.)

16 Plugin nut 17 Collar nut 18 Holder

4 4 1

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

68 17 19 Removing and installing center console (front section)

1567

68 17 19 Removing and installing center console

68 17 19 Removing and installing center console

1568

einordnung

Note Before removal, the centre console must be partly disassembled. For this purpose, remove both the front covers and the front trim. => Removing and installing center console (front section)

No. Designation 1 Shift lever knob 2 3 4 5

Clip Fastening screws Ashtray insert 1 Expanding nut 2

Qty. Removal 1 Disengage from the clips 2 all the way round. Pull the shift lever knob 1 upwards and out. 4 3 Undo. Lift out. Press out.

Installation Push on.

Inspect and replace if necessary. Screw in. Press in. Press in. 1569

68 17 19 Removing and installing center console

einordnung 6 Ashtray retaining bracket 1 Unclip the ashtray retaining bracket 6 upwards from the centre console and disconnect the electrical plug connections. Connect the electrical plug connections, secure the ashtray retaining bracket 6 in the centre console and fasten with the fastening screws 3 .

7 8

Rubber insert 1 Floor 1 oddments tray Coin box 1

Undo fastening screw 3 from the Position the floor oddments tray 8 in floor oddments tray 8 . the centre console and fasten with the fastening screw 3 . Unclip the coin box 9 and undo Tighten the fastening screw 3 and clip the fastening screw 3 the coin box 9 into place. underneath.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

68 17 19 Removing and installing center console

1570

68 30 19 Removing and installing cup holder

Removing cup holder Installing cup holder

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Removing cup holder

68 30 19 Removing and installing cup holder

1571

einordnung

1. Removing cup holder 701837 Removing cover and centre nozzle for the instrument panel Press metal clip 1 arrow and hold. Pull the cup holder 2 out of the retaining 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 centre nozzle for the instrument panel

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996430, 996431, 996630, 996631

Removing cup holder

1572

69 11 19 Removing and installing front threepoint belt

Removing front threepoint belt Installing front threepoint belt

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Removing front threepoint belt

69 11 19 Removing and installing front threepoint belt

1573

einordnung

No. Procedure Instructions Removing sidepanel 707519 Removing and installing sidepanel lining lining Removing Bpillar 705719 Removing and installing trim of A, B and Cpillars trim 1 Removing seat belt and Press out the covering cap 1 with a screwdriver. Unscrew fastening fitting screw 2 . Remove the seat belt with fitting 4 and spacer sleeve 5 . Removing belt => Removing belt tensioner tensioner Only on vehicles with belt tensioner 2 Removing automatic Unscrew fastening screw 6 from the automatic belt device 7 . belt device 3 Removing deflector Unscrew fastening screws 8 from the deflector 9 .

Removing front threepoint belt

1574

einordnung

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Installing front threepoint belt

No. Procedure Instructions Only on vehicles with => Removing belt tensioner belt tensioner Installing belt tensioner 1 Installing deflector Position the deflector and the seat belt on the inner side section and screw tight with the fastening screws 8 . Tightening torque: 10 Nm (7.5 ftlb.) 2 Installing front threepoint belt 1575

einordnung Installing automatic belt device Position the automatic belt device 7 . Make sure that the locking tab arrow of the automatic belt device is engaged correctly in the sheetmetal bracket. Tightening torque: 50 Nm (37 ftlb.) Make 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.) 705719 Removing and installing trim of A, B and Cpillars

Removing seat belt and fitting

Removing Bpillar trim Removing sidepanel 707519 Removing and installing sidepanel lining lining

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Installing front threepoint belt

1576

69 11 19 Removing and installing front threepoint belt Cabriolet

Removing front threepoint belt Installing front threepoint belt

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Removing front threepoint belt

69 11 19 Removing and installing front threepoint belt Cabriolet

1577

einordnung

No. Procedure Instructions 1 Removing seat belt and Press out the covering cap 1 with a screwdriver. Unscrew fastening fitting screw 2 . Remove the seat belt with fitting 4 and spacer sleeve 5 . Removing sidepanel Removing sidepanel lining, 707519 lining 2 Removing deflector Unscrew fastening screws 6 from the deflector 7 . Removing belt => Removing belt tensioner tensioner Only on vehicles with belt tensioner 3 Removing automatic Unscrew fastening screw 6 from the automatic belt device 9 . belt device

top of page Removing front threepoint belt 1578

einordnung

Installing front threepoint belt

No. Procedure Instructions Only on vehicles with belt tensioner Installing belt tensioner 1 Installing automatic Position automatic belt device 9 . Make sure that the locking tab belt device 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 deflector 7 and the seat belt on the inner side section and screw tight with the fastening screws 6 . Tightening torque: 10 Nm (7.5 ftlb.) Installing front threepoint belt 1579

einordnung Installing sidepanel Removing sidepanel lining, 707519 lining Installing seat belt Make sure that the belt strap can run properly! and fitting 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 torque: 50 Nm (37 ftlb.)

996620, 996621, 996650, 996651, 996630, 996631

Installing front threepoint belt

1580

69 11 01 Checking seat belts

Caution Checking belt strap Checking automatic belt device (locking effect) Belt buckle, visual inspection Belt buckle, function test Checking sash guides Checking mounting elements and mounting points CAUTION After any accident, the seat belt system must be checked systematically for proper function and damage. If damage is found according to the test points, the entire seat belt 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 elements and mounting points Note In the case of damage which does not occur as the result of an accident, e.g. wear, only the damaged part needs to be replaced.

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Checking belt strap

Pull out the belt strap on the automatic belt device fully. Check the belt strap for soiling; clean, if necessary, with mild soap suds. When drying, avoid direct sunshine.

1. Damage type 1 69 11 01 Checking seat belts 1581

einordnung If one of the damage types shown below Figure 1 and 2 is found on an accident vehicle, the seat belt and belt buckle must be replaced.

3. Damage type 2 If damage such as Figure 1, 2, 3 is found on a vehicle not involved in an accident, it is sufficient to replace the damaged seat belt.

4. Damage type 3 Burn marks from cigarettes, or similar.

5. Damage 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 automatic belt device has two locking functions The first locking function is triggered by pulling the seat belt out quickly (belt extension acceleration). Test Pull the seat belt out of the automatic belt device with a strong pull. If no locking effect occurs, the entire seat belt and belt buckle must be replaced.

Checking belt strap

1582

einordnung In the case of faults in the extension or retraction of the seat belt, check whether the locking tab of the automatic belt device is engaged correctly in the sheetmetal bracket on the body. The second locking function is triggered by a change in the sequence of vehicle movement (vehicledependent locking function). Test CAUTION For safety reasons, this driving test must be carried out on a trafficfree road, so that there is absolutely no danger to other road users. Fasten the seat belt. Accelerate the vehicle to 20 km/h (12 mph) and then perform an emergency stop with the foot brake. If the belt is not locked by the blocking mechanism during the braking phase, the entire seat belt and belt buckle must be replaced.

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Belt 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.

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Belt buckle, function test

Checking belt buckle Push the buckle into the belt buckle until it engages audibly. Check whether the lock mechanism has engaged by pulling strongly on the belt strap. If the buckle fails to lock in the belt buckle even just once in at least 5 test procedures, the entire seat belt and belt buckle must be replaced. Checking belt buckle release Release the seat belt by pressing with a finger on the button on the belt buckle. Carry out the test procedure at least 5 times. If the buckle fails to jump out even just once, the entire seat belt and belt buckle must be replaced. Note Lubricants must never be used to remedy noises or sluggishness of the buttons on the belt buckles.

Checking automatic belt device (locking effect)

1583

einordnung

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Checking sash guides

Plasticcoated covers show fine, parallel scores after the belt system has been subjected to stress (seat belt buckled during accident). On the other hand, wear caused by frequent use is indicated by a stripefree, smooth surface. Inspect the sash guides for distortion, flaking and crack formation. In the case of scoring and/or damage, the entire seat belt and belt buckle must be replaced.

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Checking mounting elements and mounting points

Check the belt buckle strap for distortion. Check the function of the height adjuster. Check the mounting points (seat, Bpillar, Cpillar, vehicle floor) for distortion or thread damage. If damage is found on the parts, the entire seat belt and belt buckle must be replaced. Replace damaged or distorted mounting points.

996421, 996420, 996430, 996431, 996630, 996631, 996620, 996621, 996650, 996651, 996840, 996841

Belt buckle, function test

1584

69 12 19 Removing and installing rear threepoint belt

Removing rear threepoint belt Installing rear threepoint belt

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Removing rear threepoint belt

69 12 19 Removing and installing rear threepoint belt

1585

einordnung

No. Procedure Removing sidepanel lining Removing Cpillar 1 Removing automatic belt device 2 Removing seat belt and fitting 3 Removing seat cushion 4 Removing the seat belt

Instructions 707519 Removing and installing wheel trim 705719 Removing and installing trim of A, B and Cpillars Unscrew fastening screw 1 from the deflector 2 . Unscrew fastening screw 3 from the automatic belt device 4 . Press out the covering cap 5 with a screwdriver. Unscrew fastening screw 6 . Remove the seat belt with fitting 7 and spacer sleeve 8 . Pull the seat cushion 9 upwards and out. Press out the cover 10 with a plastic spatula. Unscrew the fastening screw 11 from the metal clip 12 and the belt buckle 13 .

Removing rear threepoint belt

1586

einordnung top of page

Installing rear threepoint belt

No. Procedure 1 Removing the seat belt 2 Installing seat cushion 3 Removing seat belt and fitting

Instructions Position seat belt 13 with the metal clip 12 , seat well and the fastening screw 11 . Position seat cushion 9 onto the Velcro fastening strip and press on.

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 member. Tightening torque: 50 Nm (37 ftlb.) Installing automatic Position the automatic belt device 7 , making sure that the locking tab belt device arrow of the automatic belt device is engaged correctly in the sheetmetal 1587

Installing rear threepoint belt

einordnung bracket. Tightening torque: 50 Nm (37 ftlb.) Removing Bpillar 705719 Removing and installing trim of A, B and Cpillars trim Removing 707519 Removing and installing wheel trim sidepanel lining

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Installing rear threepoint belt

1588

69 12 19 Removing and installing rear threepoint belt Cabriolet

Removing rear threepoint belt Installing rear threepoint belt

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Removing rear threepoint belt

69 12 19 Removing and installing rear threepoint belt Cabriolet

1589

einordnung

No. Procedure Moving Cabriolet convertible top to service position Removing rear wall lining and cover 1 Removing seat cushion 2 Removing belt buckle

Instructions 610119, Cabriolet Verdeck aus und einbauen

=> Removing rollover protection system Pull the seat cushion 1 upwards and out. Press out the cover 2 with a plastic spatula. Unscrew the fastening screw 3 from the metal clip 4 and the belt buckle 5 . Press out the covering cap 6 with a screwdriver. Unscrew fastening screw 7 . Remove the seat belt with fitting 8 and spacer sleeve 9 . Unscrew fastening screw 10 from the automatic belt device 11

Removing seat belt and fitting Removing automatic belt

Removing rear threepoint belt

1590

einordnung device A . Remove automatic belt device 11 at the side B .

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Installing rear threepoint belt

No. Procedure Instructions 1 Installing automatic Position automatic belt device 1 A . Make sure that the locking tab belt device arrow 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 Make sure that the belt strap can run properly! and fitting Screw the fastening screw 5 , the seat belt with fitting 4 and the spacer sleeve 3 tight on the inner lower side member and press in the cover 6 . Installing rear threepoint belt 1591

einordnung Tightening torque: 50 Nm (37 ftlb.) Screw the belt buckle 7 and the metal clip 8 tightly to the seat well with the fastening screw 9 and press in the cover 10 . Tightening torque: 50 Nm (37 ftlb.) Press the seat cushion 11 on to the Velcro fastenings. => Installing rollover protection system

Installing belt buckle Installing seat cushion Installing the rear wall lining and cover

996310, 996311, 996610, 996611

Installing rear threepoint belt

1592

69 13 19 Removing and installing belt tensioner as of MY 2002

Removing belt tensioner Installing belt tensioner

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Removing belt tensioner

Note As from model year 2002, the front threepoint 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 can be read out with the Porsche System Tester using the airbag control module (POSIP). 69 13 19 Removing and installing belt tensioner as of MY 2002 1593

einordnung Observe the direction of travel arrow 3 . => Safety regulations for vehicles with airbag and belt tensioner => Disposal of airbag and belt tensioner units => Removing and installing front threepoint belt

1. Pull belt 1 forwards. 2. Disable the fuse 2 for the electrical plug on the belt tensioner 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 tensioner

=> Safety regulations for vehicles with airbag and belt tensioner

1. Install belt tensioner. Observe the direction of travel 3 . 2. Screw fastening screw B , tightening torque 50 Nm (37 ftlb.). 3. Insert electrical plug A in the belt tensioner.

Removing belt tensioner

1594

einordnung

4. Push in fuse 2 with e.g. a screwdriver in the direction of travel until the fuse engages. 5. By gently pulling 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 threepoint belt

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431, 996630, 996631, 996620, 996621, 996650, 996651

Installing belt tensioner

1595

69 36 19 Removing and installing adjustment fitting (seat belt height adjuster)

Removing and installing adjustment fitting Illustrated on Targa (996)

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Removing and installing adjustment fitting

69 36 19 Removing and installing adjustment fitting (seat belt height adjuster)

1596

einordnung

No. Designation 1 Fastening screw Adjustment fitting

Note: Qty. Removal Installation 705719 Removing and installing Bpillar 1 Unscrew fastening screw 1 . Screw in fastening screw 1 and tighten. Tightening torque: 23 Nm (17 ftlb.) 1 Guide the adjustment fitting 2 Insert the adjustment fitting 2 upwards out of the Bpillar in the downwards into the Bpillar in the direction of the arrow . direction of the arrow . Tighten fastening screw 1 .

996430, 996431, 996420, 996421, 996450, 996451

Removing and installing adjustment fitting

1597

69 51 19 Removing and installing sensor for side airbag

Remove sensor for side airbag Install sensor for side airbag Tools

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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 righthand sides in the vehicle. 69 51 19 Removing and installing sensor for side airbag 1598

einordnung After an accident, the sensor of the triggered side airbag unit must be examined for damage and replaced if necessary. The sensor must be replaced after the side airbag has been triggered for the third time Safety conditions must be observed when handling airbags. => Safety regulations for vehicles with airbag and belt tensioner Remove front seat. 7, 720119 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 the support and lay it in the vehicle interior.

2. Unlock locating peg 1 of the support using the commercially available removal tool. => Tools

3. Unscrew fastening screws 2 and nuts 3 and carefully pull the support up and out of the retaining points.

4. Loosen the electrical plug connection on the airbag sensor.

Remove sensor for side airbag

1599

einordnung

5. Remove both fastening screws and remove the sensor. top of page

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 lower side member.

Install sensor for side airbag

1600

einordnung

4. Push in the locating peg 1 of the support and check that it is sitting correctly. 5. Tighten the fastening nuts 3 and the fastening screws 2 . Tightening torque 2 7.2 Nm (5.5ftlbs.). 6. Lay the floor covering over the support and engage. Using the Porsche System Tester, read out any 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 installing side panel lining Install front seat. 7, 720119 Removing and installing front seat

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Tools

Item

Special tool designation Removal tool

Remarks Commercially available HandbuchWerkstattausrstung Kapitel 2.4, Nr. 21

996420, 996421, 996450, 996451

Tools

1601

69 72 19 Removing and installing rollover bar

Safety instructions for work on the rollover protection system Mechanical emergency triggering of the rollover protection system Removing rollover protection system Installing rollover protection system Tightening torques

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Safety instructions for work on the rollover protection system

It is impermissible to perform repairs on the rollover bar modules. The rollover bar modules must be replaced in the event of visible damage or pressure marks.

69 72 19 Removing and installing rollover bar

1602

einordnung WARNING Danger of injury during work on the rollover protection system! The movement range of the rollover protection system must be kept clear. Work on the rollover protection system must be performed only with the ignition key withdrawn. Please note: Do not begin assembly work until after a waiting time of 1 minute has elapsed. Tools or other objects must not be placed in the extension area of the rollover protection system. WARNING Danger of injury during work on the rollover protection system! Remove the rollover bar modules only after the rollover bar has been extended (triggered). After assembly work on the rollover protection system but at least every 2 years the function of the rollover protection system must be tested by triggering it via the diagnostic interface of the Porsche System Tester. Perform the function test on the rollover protection system only with the hardtop and covering cap removed and the convertible top open.

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Mechanical emergency triggering of the rollover protection system

If the rollover bar modules cannot be triggered via the diagnostic interface, mechanical emergency triggering is possible. WARNING Danger of injury during mechanical emergency actuation! The movement range of the rollover protection system must be kept clear.

Insert a screwdriver into the hole in the module and press it against the top edge of the pawl. Press the screwdriver to the right arrow A and hold it while pressing up arrow B . The rollover protection system is released. top of page

Safety instructions for work on the rollover protection system

1603

einordnung

Removing rollover protection system

WARNING Danger of injury during assembly work! The rollover bar module can be triggered. Remove the rollover bar modules only after the rollover bar has been extended (triggered).

No. 1

Procedure Removing rear wall lining

Instructions Remove fastening screws 1 from the rear wall lining 2 on the left and right, and detach the auxiliary frame. Remove rear wall lining.

Removing cover 1604

Removing rollover protection system

einordnung Unclip covering caps 3 . Unclip the cover 4 over the rollover protection 5 at the front, unscrew the fastening screws 6 and lift the cover up and off. Note: Actuate the rollover protection system 5 only if: the hardtop is removed the convertible top is open the caps are removed

Triggering rollover protection system with the Porsche System Tester 2

4 5

Undoing fastening screws Disconnecting the electrical plug connection

Connect the Porsche System Tester to the diagnostic socket. Switch on ignition. Select menu item "Rollover protection". Select menu item "Drive links" in the command line which then appears. Press the key combination described in the Tester; the rollover protection system is triggered. Undo the fastening screws from the modules in the auxiliary frame 8 and pull out in downward direction. Press the electrical plug connection 9 arrow A and pull apart.

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Installing rollover protection system

Installing rollover protection system

1605

einordnung

No. 1 2

Procedure Connecting electrical plug connection Fitting rollover bar modules

Triggering rollover protection system with the Porsche System Tester 2

Instructions Plug in electrical plug connection 9 of the rollover bar modules. Position the rollover bar modules on the auxiliary frame 8 and fasten them with the fastening screws 7 property class 10.9. Tightening torque 33 Nm (24 ftlb) 3 Nm (2 ftlb). Test the rollover protection system 5 (function test). Select menu item "Rollover protection". Select menu item "Drive links" in the command line which then appears. Press the key combination described in the Tester; the rollover protection system is triggered. Note: Carry out the function test only with the cover caps removed.

Fitting cover 1606

Installing rollover protection system

einordnung Position cover 4 of the rollover protection system over the auxiliary frame and screw it down with the fastening screws6 Press locking levers of the rollover bar modules outward, and press in the rollover bar until it engages. Press locking levers outward and press in the rollover bar until it can be felt to engage. Fit cover flaps 3 on the left and right. Position rear wall lining 2 on the auxiliary frame and fasten it on the left and right using the 1 fastening screws.

Press in the rollover bar

Fitting rear wall lining

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Tightening torques

Location Attaching the rollover bar modules to the auxiliary frame

Illustration Thread 7 M8

Tightening torque [Nm] (ftlb.) 33 (24) 3 (2)

996630, 996631, 996420, 996421, 996450, 996451

Tightening torques

1607

69 74 19 Removing and installing control module for rollover protection system

Removing control module Installing control module Tools and materials top of page

Removing control module

1. Remove ignition key 2. Disconnect the battery and cover terminal or battery. 3. Only loosen the centre console and move it forwards a little. => Removing and installing center console 4. Remove the two rear belt buckles and take out the seat wells. 5. Undo the trim of the seat wells from the carpeting and lift up in the middle.

6. Using 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 shearoff nuts with socket wrench insert => Tools and materials, and remove the rollover protection control module. top of page

Installing control module

1. Install the rollover protection control module in the centring holes with the fixing pins, and secure with shearoff nuts. 2. Use a 1/4 inch Allen key to tighten the shearoff nuts. 3. Engage electrical plug connection and route wire carefully. Install control module cover, seat wells, belt buckles and centre console. 69 74 19 Removing and installing control module for rollover protection system 1608

einordnung 4. Following the installation of a new control module for the rollover protection system, the transport lock must be deactivated with the Porsche System Tester 2 (refer to Group 01, Entire vehicle General, Sales check: Deactivating the transport lock in the rollover protection system, 911 Cabriolet top of page

Tools and materials

Item 1

Special tool designation Socket wrench insert 9259

Remarks Gr. 2.2.2; Workshop Equipment Manual

996620, 996621, 996650, 996651, 996630, 996631

Installing control module

1609

69 77 19 Removing and installing frame for rollover protection system

Removing and installing frame for rollover protection system Tightening torques

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Removing and installing frame for rollover protection system

69 77 19 Removing and installing frame for rollover protection system

1610

einordnung

No. Designation 1 Fastening screw 2 Fastening nut 3 Frame

Qty. Removal 4 Unscrew. 4 Unscrew. 1 Undo fastening screws 1 and fastening nuts 2 , and lift frame 3 out of the vehicle.

Installation Tighten. => Tightening torques Tighten. => Tightening torques Position frame in the vehicle. Dimension X: 491 1 mm Measure centre of screwed point (convertibletop support), side section on inside, to frame cutout on right and left. Tighten fastening screw 1 and fastening nut 2 .

4 5 6 7

Fastening nut Relay carriers Wiring harness Ovalhead screw

2 1 1 10

Removing and installing frame for rollover protection system

1611

einordnung 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Convertibletop 1 control module Fastening screw 4 Holder 2 Fastening screw 4 Right bracket 1 Left bracket 1 Clip 2 Fastening screw 1 Belt reel, left 1 Assembly key 1 Clip 2 Holder 1 DME + Tiptronic 1 control unit Collar nuts 2 Z drive VDKD cpl. 1 Convertible top Z 1 drive Fastening nut 4

=> Tightening torques => Tightening torques

Inspect and replace if necessary. => Tightening torques Clip in. Inspect and replace if necessary.

=> Tightening torques

=> Tightening torques

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Tightening torques

Location Illustration Hexagonhead bolts for installing the rollover bar 1 Collar nuts for installing the rear Zsupports 2 Hexagonhead bolt for installing the holder 10 9 Hexagonhead bolt for installing the bracket on the right 11 and left 12, 13 Hexagonhead bolt 15 Collar nuts for installing the DME + Tiptronic control unit 21 on the holder Collar nuts for installing the convertible top Z drive 24

Thread M10 M10 M6 M6

Tightening torque [Nm] (ftlb.) 65 (48) 6 (4.5) 48 (36) 9.7 (7) 9.7 (7) 50 (37) 7 (5) 6 (4.5)

M6 M6

996620, 996621, 996650, 996651, 996630, 996631

Tightening torques

1612

70 05 19 Removing and installing front luggage compartment trim

Removing and installing trims units Removing and installing carpet lining Tools and materials

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Removing and installing trims units

70 05 19 Removing and installing front luggage compartment trim

1613

einordnung

No. 1 2 3 4 5 6

Designation Cam Interior light Fastening screws Trim units Holder Holder

Qty. 2 1 3 1 2 2

Removal Turn 90 and remove. Press out. Unscrew. Unscrew fastening screws 3

Installation Position and turn 90. Press in. Screw in. Screw in fastening screws 3 .

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Removing and installing trims units

1614

einordnung

Removing and installing carpet lining

No. 1 2 3 4 5 6 7 8

Designation Plug Short plastic nuts Cover cap Fastening screw Panel Front carpet lining Rear carpet lining Bottom carpet lining

Qty. 4 1 2 1 1 2 2 1

Removal Removal tool: => Tools and materials Unscrew. Unscrew.

Installation Press in. Screw in. Screw in.

Removing and installing carpet lining

1615

einordnung 9 10 Fastening nut Holder 1 1

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Tools and materials

Item 1

Special tool designation Removal tool, universal no. 21

Remarks Gr. 2.4; Workshop Equipment Manual

996430, 996431, 996630, 996631, 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Tools and materials

1616

70 18 19 Removing and installing the instrument panel and instrument panel bracket as of model year 2003
Removing and installing the instrument panel Removing and installing the instrument panel bracket Tightening torque Tools and materials

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70 18 19 Removing and installing the instrument panel and instrument panel bracket as of model 1617 year 200

einordnung

Removing and installing the instrument panel

Note Before removing the instrument panel, it must be disassembled. => Disassembling the instrument panel

No. Designation 1 Fastening screws

Fastening screws

Qty. Removal 3 Unscrew fastening screws 1 from the instrument panel 4 . 13

Installation Screw the instrument panel 4 to the instrument panel bracket with the fastening screws 1 .

Removing and installing the instrument panel

1618

einordnung Undo fastening screws 2 Screw the instrument panel 4 to the from the instrument panel instrument panel bracket with the 4 . fastening screws 2 . Unscrew the fastening screws Tighten the fastening screws 2 . 2 . See: Position 1 and 2 See: Position 1 and 2 Unscrew the fastening screws Inspect and replace if necessary. 2 .

3 4 5 6

OnBoard Diagnosis (OBD) socket Instrument panel Sheetmetal nut Instrument panel bracket with knee protector strip Sheetmetal nut

1 1 2 1

11

Unscrew fastening screws 1 Inspect and replace if necessary. and 2 from the instrument panel 4 .

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Removing and installing the instrument panel bracket

Removing and installing the instrument panel bracket

1619

einordnung

Note Before removing the instrument panel bracket, the instrument panel must be disassembled. => Removing and installing the instrument panel bracket

No. 2 7 8 9

Designation Fastening screws Sheetmetal nut Fastening screws Threaded plate

Qty. Removal 4 4 4 4

Installation

=> Tightening torque It is screwed into position with the compensating element 10 and the fastening screw 8 .

10

4 1620

Removing and installing the instrument panel bracket

einordnung Compensating element 11 Fastening screws 2 12 Instrument panel 1 bracket The compensating element 10 By screwing in the fastening screws is released by undoing the 8 , the compensating element 10 fastening screw 18 . can be fixed and secured. => Tightening torque Undo the fastening screws 8 Insert instrument panel bracket 12 in the compensating elements into the body. Fix compensating 10 and guide the instrument elements 10 to the instrument panel panel bracket 12 out of the bracket and screw down with the body. fastening screws 8 and 11 . Pull out. Press in. Only installed on 911 coup versions. Check, if necessary, replace. => Tightening torque Unscrew fastening screws 15 Secure the knee protector strip 16A on the instrument panel bracket 12 from the knee protector strip and tighten the fastening screw 15 . 16A . Remove the knee protector strip. Unscrew fastening screws 15 Secure the knee protector strip 16B on the instrument panel bracket 12 from the knee protector strip and tighten the fastening screw 15 . 16B . Remove the knee protector strip. Is destroyed when removed. Tighten protective film. Is destroyed when removed. Attach the adhesive pad for lefthand drives on the right holder and on the left holder for righthand drives.

13A Closure cap 13B Plug

2 2

14 Sheetmetal clip 4 15 Fastening screws 4 16A USA version, 1 knee protector strip 16B USA version, knee protector strip 1

17 Cowl panel seal 1 18 Adhesive pad 1

The bonding area must be free of dust and grease. Tighten protective film and position it. => Tools and materials 19 Clip 4 20 Fastening screws 4 21 Shearoff nut 2 => Tightening torque Undo the shearoff nut with special tool 9259. => Tools and materials See: 695319 Removing and See: 695319 Removing and installing installing the triggering unit for the triggering unit for the airbag. the airbag. Fix the cover panel in the body and the instrument panel bracket 12 and screw down with the fastening screws 20 . => Tightening torque 1621

23 Airbag control module 24 Cover panel

25 Fastening screws 2

Removing and installing the instrument panel bracket

einordnung 26 Cover panel 27 Strut 1 1 Unscrew fastening screws 25 . Unscrew fastening screws 2 Position strut 27 on the instrument from the strut 27 on the left panel bracket 12 and tighten with the and right. fastening screws 2 .

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Tightening torque

Tightening torque [Nm] Location Illustration Thread (ftlb.) Apillar 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 strip fastening nuts on the instrument panel 14 M6 10 (7.5) Nm bracket (ftlb.) Knee protector fastening screws on the instrument panel 15 M8 6 (4.5) Nm bracket (ftlb.) Cover panel fastening screws on the instrument panel bracket 20 M6 10 (7.5) Nm (tunnel) (ftlb.) Cover panel fastening screws on the instrument panel bracket 26 M6 10 (7.5) Nm (ftlb.)

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Tools and materials

Cutting with adhesive pad X 50 mm Y 40 mm Z 25 mm Punch out the crack Z at a diameter of 7 mm Tightening torque 1622

einordnung Item 1 2 Special tool designation Socket wrench insert 9259 Adhesive pad, commercially available Teflon adhesive tape Remarks Gr. 2.2; Workshop Equipment Manual Cutting with adhesive pad

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

Tools and materials

1623

70 41 19 Removing and installing floor covering

70 41 19 Removing and installing floor covering

1624

einordnung

Before removing the floor covering 11 , the following components must be removed. => Removing and installing front seat 681719 Removing and installing centre console 681719 Removing and installing centre console front section 691119 Removing and installing front threepoint belt No. 1 2 3 4 5 Designation Plastic cover Plugin terminal Fastening screw Fuse box covering frame Fuse box Qty. 1 1 4 1 1 Removal Installation Pull off plastic cover of the handle Attach plastic cover. hole. Unscrew. Screw in.

70 41 19 Removing and installing floor covering

1625

einordnung 6 7 Fastening screw Foot rest cover 3 1

Foot rest

Unscrew fastening screws 6 and Install the foot rest cover 7 remove foot rest cover 7 . after the floor covering is fitted 11 . Install the foot rest 8 before the floor covering is fitted 11 . 551037 Disassembling and assembling release for lid 680519 Removing and installing 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 B See: Section A A Closing the Velcro fastening arrow . Install the holder left floor 13 before the floor covering is fitted 11 .

9 10

Grommet 1 Assembling release for lid

11

Floor covering

See: Section A A Opening the Velcro fastening arrow .

12 13

Fastening screw Holder, floor left

1 1

996420, 996421, 996450, 996451, 996840, 996841, 996430, 996431

70 41 19 Removing and installing floor covering

1626

70 57 19 Removing and installing trim of A, B and Cpillars

Removing and installing trim of A, B and Cpillars Installing trim of A, B and Cpillars

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Removing and installing trim of A, B and Cpillars

70 57 19 Removing and installing trim of A, B and Cpillars

1627

einordnung

No. 1 2 3

4 5

Instructions Lift up the clothes hook bracket 1 at the bottom with a plastic spatula and pull up and off. Pressing out seat belt height adjuster Press seat belt height adjuster release 3 out of the release hexagonhead bolt 4 using a screwdriver. Removing Bpillar trim Undo hexagonhead bolt 4 of the sash guide mount 5 . Undo fastening screw 6 . Lift up Bpillar trim 7 and remove. Unclipping the Cpillar trim Pull Cpillar trim 10 inwards. Unclip the Apillar trim. Pull the Apillar trim 11 inwards along the roof frame and windscreen frame.

Procedure Unclipping clothes hook bracket

top of page Removing and installing trim of A, B and Cpillars 1628

einordnung

Installing trim of A, B and Cpillars

No. Procedure 1 Clipping in Apillar trim

2 3

Clipping in Cpillar trim Installing sash guide mount and Bpillar

Instructions Note: before installation, check that the deformation element is seated properly A . Check sheetmetal clips 9 and replace if necessary. Insert the Apillar trim 11 at the side of the windscreen frame (transition point to dashboard), clip in the Apillar trim along the roof frame. Check sheetmetal clips 9 and replace if necessary. Position and clip in the Cpillar trim 10 on the Cpillar. Push sleeve 8 onto the lug of the Bpillar trim 7 and insert in the bottom of the Bpillar. 1629

Installing trim of A, B and Cpillars

einordnung trim Press in the two clips 2 at the top and tighten Bpillar trim with the fastening screw 6 . Position sash guide mount 6 on the Bpillar and tighten with the hexagonhead bolt 4 . Tightening torque: 50 Nm (37 ftlb.) Pushing on seat belt Insert peg of the seat beat height adjuster release 3 into the height adjuster release hexagonhead bolt bore 4 . Note: The seat belt height adjuster release must not be separated. If the cover of the retaining frame loosens when removing, the seat belt height adjuster release 3 must always be replaced.1) Fitting the clothes Insert the clothes hook bracket 1 carefully into the aluminium bracket at hook bracket the top. Note: The clothes hook bracket 1 must be inserted into the aluminium bracket without the use of force, otherwise the aluminium bracket is deformed. Carefully press the clothes hook bracket into the sheetmetal clips at the bottom 2 of the B pillar trim 7 .

1) In

the model year 2001, the seat belt height adjuster release 3 changed. The cover is now affixed on to the retaining frame.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Installing trim of A, B and Cpillars

1630

70 57 19 Removing and installing Apillar trim Cabriolet

Removing Apillar trim Installing Apillar trim Tightening torques

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Removing Apillar trim

70 57 19 Removing and installing Apillar trim

Cabriolet

1631

einordnung

No. Procedure 1 Removing convertibletop peg housing 2 Unclipping the Apillar trim 3 Removing the Apillar trim

Instructions Unscrew fastening screw 1 from the convertibletop peg housing 2 . Pull the Apillar trim 3 inwards along the windscreen frame in the direction of arrow . Remove the Apillar trim 3 upwards in the direction of the arrow .

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Installing Apillar trim

Removing Apillar trim

1632

einordnung

No. Procedure 1 Installing Apillar trim

2 3

Clipping in Apillar trim Installing convertibletop peg housing

Instructions Before installation, check that the deformation element is seated properly 4 . Check sheetmetal clips 5 and replace if necessary. Insert the Apillar trim 3 at the side of the windscreen frame (transition point to instrument panel) in the direction of the arrow . Clip in the Apillar trim 3 along the roof frame in the direction of arrow . In order to avoid rattling noises, each of the convertibletop peg housings on the left and right 2 must be facing outwards, in relation to the centring pins fitted on the convertible top or hardtop, when tightening. The convertible top must be closed or the hardtop must be fitted to check the adjustment. Tighten the fastening screws 1 . => Tightening torques 1633

Installing Apillar trim

einordnung

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Tightening torques

Location Fastening screw for convertibletop peg housing to cowl panel frame

Illustration Thread 1 M6

Tightening torque [Nm] (ftlb.) 10 (7.5)

996630, 996631, 996620, 996621, 996650, 996651

Tightening torques

1634

70 75 19 Removing and installing sidepanel lining

Removing sidepanel lining Installing sidepanel lining

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Removing sidepanel lining

70 75 19 Removing and installing sidepanel lining

1635

einordnung

No. Procedure Removing Bpillar 1 Pulling off cover 2 Undoing fastening screw 3 Undoing sidepanel lining

Instructions => Removing and installing trim of A, B and Cpillars Pull cover 2 up and off arrow . Undo ovalhead screw 3 from the sidepanel lining. Unscrew hexagon socket head bolt 5 , remove cover trim 6 . Pull out locking tabs of the sidepanel lining 1 from the clips in the rear side panel arrow . Lift locking tabs of the sidepanel on the lower side member and pull out. Disconnecting the electrical plug Press the lug small arrow of the electrical plug connection connections for the loudspeaker 7 and separate.

top of page Removing sidepanel lining 1636

einordnung

Installing sidepanel lining

No. Procedure 1 Connecting the electrical plug connections 2 Sidepanel lining

Instructions Connect the electrical plug connections for the loudspeaker 7 until the lug of the plug connection engages.

3 4

Position the sidepanel 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 bolt 5 . Tightening fastening Position the ovalhead screw 3 in the sidepanel lining and tighten. screw Fitting cover Position the locking tabs of the cover 2 on the sidepanel lining arrow and press in. 1637

Installing sidepanel lining

einordnung 5 Fitting seal Installing Bpillar Lift up the pillar seal along the sidepanel lining using a plastic spatula arrow . => Installing trim of A, B and Cpillars

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Installing sidepanel lining

1638

70 75 19 Removing and installing sidepanel lining Cabriolet

Removing sidepanel lining Installing sidepanel lining

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Removing sidepanel lining

70 75 19 Removing and installing sidepanel lining

Cabriolet

1639

einordnung

No. Procedure Opening convertible top 1 Folding over emergency seat backrest 2 Removing holding pegs and cover 3 Pulling off cover 4 Removing sidepanel lining

Instructions

Unlock emergency seat backrest and fold over.

Unscrew holding pegs 2 with Allen key St6. Remove cover 3 . Pull cover 4 out of the clips to the front 5 . Unscrew fastening screw 6 from the sidepanel lining 1 . Press out collar 7 with a plastic spatula. Loosen the fastening screws 9 from the loudspeakers. Unscrew the fastening screw 12 underneath from the sheetmetal bracket of the side panels 1 . Press and disconnect the locking tab 11 of the electrical plug connection for the loudspeaker. Pull the sidepanel lining 1 inwards until the clip 8 disengages. 1640

Removing sidepanel lining

einordnung Subsequently lift the trim at the bottom and remove towards the front.

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Installing sidepanel lining

No. Procedure Instructions 1 Mounting the Insert pegs of the sidepanel lining 1 on the inside of the rear side section and sidepanel lining on the frame of the rollover protection. Press clip 8 into the inside rear side section. Clip must engage audibly. Position fastening screw 12 into the sheetmetal bracket in the cutout for the loudspeaker, and tighten. Plug in electrical plug connection 11 of loudspeakers. Position the loudspeaker in the sidepanel 1 and fasten with the fastening screws 9 . 2 Fitting holding Position the cover trim 3 and the holding peg 2 in the cutout of the pegs and cover sidepanel lining and screw in Installing sidepanel lining 1641

einordnung tightening torque 20 Nm (15.0 ftlb.) Press in collar 7 , collar must engage audibly. Check the clips 5 or replace. Fasten the sidepanel lining with the fastening screw 6 . Press the locking tabs of the cover 4 into the clips 5 . Lift up the pillar seal along the sidepanel lining using a plastic spatula arrow .

Fitting cover

Fitting seal Closing convertible top

996630, 996631, 996620, 996621, 996650, 996651

Installing sidepanel lining

1642

70 84 19 Removing and installing Cabriolet roof lining

Removing roof lining, front 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 lining

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70 84 19 Removing and installing Cabriolet roof lining

1643

einordnung

Removing roof lining, front

CAUTION Avoid damage to or destruction of the tension bow seal. The following procedure Convertible top in service position must be observed! Move convertible top to the rear by means of the electric motor until the convertibletop compartment lid has reached the rear end position. Move convertible top forward by means of the electric motor until the convertibletop compartment lid moves forward, then interrupt closing operation. Disengage left and right tension cables and fold up the tension bow. The convertible top must no longer be electrically operated in this position.

Removing roof lining, front

1644

einordnung No. Procedure Convertible top in service position Instructions Move convertible top to the rear by means of the electric motor until the convertibletop compartment lid has reached the rear end position. Move convertible top forward by means of the electric motor until the convertibletop compartment lid moves forward, then interrupt closing operation. Disengage left and right tension cables and fold up the tension bow. The convertible top must no longer be electrically operated in this position. Removing Unscrew fastening screws 1 and remove convertibletop lock 2 . convertibletop lock Disconnect electrical plug connection 3 . Unscrewing fastening Unscrew the fastening screws 4 at the left and right. screws Pulling off front Pull off sewnon clamping rail 5 of the roof lining on front roof frame 1 clamping rail on the left and right. Pulling off the Pull off sewnon clamping rail 6 of the roof lining on rear roof frame 1 clamping rail at the on the left and right. rear Removing roof lining Unscrew the expanding nuts 7 from the covering strip 8 and the rear connection on front roof frame 1. roof frame 1

1 2 3 4

Removing roof lining, front

1645

einordnung

No. Procedure 6 Removing clamping rail connection from the main bow

7 8 9

Instructions Unscrew fastening screws 9 on the left and right. Pull off connection of clamping rail 10 from the main bow in direction of arrow . Opening the Velcro fastening of Open the velcro fastenig on the side roof lining on the left and the side roof lining right. See: => Removing and installing side roof lining Opening the Velcro fastening Open the velcro fastening 13 of the roof lining on the corner bow. Removing bracing straps Unscrew fastening screw 14 from the bracing straps X, Y . Removing roof lining connection Press the connection strip 15 of the roof lining out of the rear at the corner bow groove of the corner bow using a plastic spatula. Pull roof lining connection 16 out of the front groove of the corner bow in direction of arrow .

top of page Removing roof lining, front 1646

einordnung

Installing front roof lining

No. Procedure Instructions 1 Installing roof lining connection Insert and centre the roof lining connection 16 into the front at the corner bow groove of the corner bow in direction of arrow . Insert the connection strip 15 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 the corner bow. 4 Installing bracing straps Position bracing strap Y underneath the bracing strap X . Observe sequence as shown in the illustration. Tighten the fastening screw 14 on main bow with the bracing

Installing front roof lining

1647

einordnung straps. Closing the Velcro fastening of Close the velcro fastening on the side roof lining on the left and the side roof lining right. See: => Removing and installing side roof lining Installing clamping rail Unscrew clamping rail connection 10 on the main bow in connection from the main bow direction of arrow Tighten the connection on the left and right with the fastening screws 9 .

No. Procedure 6 Installing roof lining connection on front roof frame 2 7 Pushing on the clamping rail at the rear 8 Installing front roof lining

Instructions Position cover strip 8 on roof frame 2. Press in expanding nuts 7 . Push sewnon clamping rail 6 of the roof lining onto the left and right of rear roof frame 1.

1648

einordnung Pushing on front clamping rail 9 Tightening front clamping rail 10 Installing convertibletop lock Push front sewnon clamping rail 5 onto the front of roof frame 1 on the left and right. Tighten the connection on the left and right with the fastening screws 4 . Plug in electrical plug connection 3 . Position convertibletop lock 2 on roof frame 1. Coat the fastening screws 1 with highstrength screw locking lacquer (Loctite 270) and tighten. Tightening torque: 8 Nm (6 ftlb.)

Ending service position

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Removing rear roof lining

Removing rear roof lining

1649

einordnung No. Procedure Opening the side Velcro fastening 1 Opening zip fastener. 2 3 4 Instructions Open the velcro fastenig on the side roof lining on the left and right. See: => Removing side roof lining Disconnect the rear roof lining from the convertibletop cover by opening the zip fastener 17 . Disconnecting pushbutton Disconnect pushbutton 18 Unscrewing the connection Unscrew fastening screw 19 from the bracing strap Z on the left and right and from the rear roof lining 21 . Removing tension hook of Bend brace 20 and remove from tension bow at the front in side metal struts direction of arrow . Remove brace from the textile case of the roof lining 21 . Opening the Velcro fastening Open the velcro fastening 22 of the tension bow. Undoing connection on Press connection 23 out of the groove on the tension bow. tension bow Pulling out connection on the Pull connection 24 carefully out of the groove on the rear rear window window.

5 6 7

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Installing rear roof lining

Installing rear roof lining

1650

einordnung

No. 1

Procedure Fitting roof lining connection for the rear window

3 4

Installing roof liner connection to tension bow Installing brace of side metal struts Tightening fastening screws

Instructions Lift the metal clips using a plastic spatula A and insert a small screwdriver under the metal clip B . Insert the connection seal 24 of the roof lining underneath the metal clips C . Ensure that the clearance cuts of the roof lining D are positioned on the electrical connection of the rear window. Subsequently knock open the metal clips with a plastic hammer. Make sure that the metal clips engage in the frame cutouts Press the roof lining connection 23 into the groove of the tension bow. Insert brace 20 into the textile case of the roof lining. Insert brace first at rear then bend and insert at front. Position the bracing strap Z underneath the roof lining 21 and scew on to the main bow with the fastening screw 19 . 1651

Installing rear roof lining

einordnung Observe sequence as shown in illlustration. Close the velcro fastening 22 of the tension bow.

5 6 7

Closing the Velcro fastening. Closing the pushbutton Closing zip fastener

Close pushbutton 18 Connect the rear roof lining to the main bow connection above the corner bow using the zip fastener 17 . Closing the Velcro Close the velcro fastening on the side roof lining on the left and fastening of the side roof right. See: => Installing side roof lining lining

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Removing and installing side roof lining

Removing side roof lining

1. Opening the Velcro fastening Disconnect the velcro fastening connection 11a between the roof lining 11 at the side and the corner bow 11b in direction of arrow .

2. Removing roof lining at sides of roof frame 3 a. Drill out the fastening rivets 12a . Remove the roof lining at the side 11 and the plastic insert 12b .

Removing and installing side roof lining

1652

einordnung

Installing side roof lining

1. Installing roof lining at sides of roof frame 3 a. Position the roof lining at the side 11 and the plastic insert 12b on the main bow. b. Rivet on to the holes provided on the main bow using the fastening rivets 12a (included 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 page

Tightening torques

Location Fastening screws of convertibletop lock on roof frame 1

Tightening torque [Nm] Illustration Thread (ftlb.) Item number 1 M6 8 (6) Nm (ftlb.)

996630, 996631, 996620, 996621, 996650, 996651

Installing side roof lining

1653

72 01 19 Removing and installing front seat

Removing front seat Installing front seat

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Removing front seat

72 01 19 Removing and installing front seat

1654

einordnung

No. Procedure 1 Remove seat rail cover

3 4

Instructions Unscrew the sheetmetal screws out of the seat rail cover at the front 2 . Pull seat rail cover on front end 2 out of the right and left seat rails in forward direction Undoing seat screws at Move seat to its rear limit position and undo the front M10 x 28 Torx front screws 3 from the right and left seat rails using an E12 socket wrench insert Undoing seat screws at Move seat to its front limit position and undo the M10 x 28 Torx screws rear 3 from the right and left seat rails using an E12 socket wrench insert Disconnecting the Release plug connector locking device on the side arrow and electrical plug connection separate the plug connection 4 .

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Removing front seat

1655

einordnung

Installing front seat

No. 1 2

Procedure Connecting electrical plug connection Fitting seat screws at rear

Fitting seat screws at front

Instructions Join the plug connection 4 , press in plug connector locking device on the side arrow . Position seat rails on the seat baseframe, 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.). Move seat to its rear limit position, screw the front 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.). 1656

Installing front seat

einordnung 4 Fit seat rail cover 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

Installing front seat

1657

72 21 19 Removing and installing cushion carrier

Removing front cushion carrier Installing front cushion carrier

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Removing front cushion carrier

72 21 19 Removing and installing cushion carrier

1658

einordnung

No. 1

3 3a

Procedure Instructions Removing control module Lift both holders of the cover 1 in direction of arrow A and and cover remove to the front. Unscrew the fastening screws 2 , position control module so that the plastic clips 9 are exposed. Removing switch for seat Unscrew fastening screw 4 from the switch for the seat adjustment adjustment 5 . Pull the switch upwards and pull to the front arrow . Subsequently remove through the opening of the cushion carrier direction of arrow . Disconnecting wiring Disconnect electrical plug connection of the seat heating, unclip harness the lines from the metal clips 6 along the seat rail. Removing wiring harness Remove wiring harness 7 from the cushion carrier; to do so, press the locking tabs arrow and pull out of the cushion carrier.

4 Removing front cushion carrier 1659

einordnung Removing seat cushion from seat frame. Insert the retainer 8 of the plastic clip 9 at the sides using a screwdriver and press out. Unclip the plastic clip 9 from the seat frame. Remove cushion carrier from the seat frame.

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Installing front cushion carrier

No. Procedure 1 Installing wiring harness 2 Installing seat cushions on to seat

Instructions 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 the line into the metal clips along the seat rails 6 . Position the seat cushion on to the seat frame and clip the plastic clip 9 into the seat frame. Push the retainer into the plastic clip 8 . 1660

Installing front cushion carrier

einordnung frame Installing switch for seat adjustment Installing control module and cover

3 4

Pull switch for seat adjustment 5 out of the inner cushion carrier opening and position. Secure the switch with the fastening screws 4 . Position control module 3 and tighten with the fastening screws 2 . Push on cover 1 in direction of arrow A .

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Installing front cushion carrier

1661

72 36 19 Removing and installing motor for the lumbar support

Removing lumbar adjustment device for the lumbar support Removing motor for the lumbar support 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 the lumbar Installing lumbar support Tools Test plan for the lumbar adjustment device

72 36 19 Removing and installing motor for the lumbar support

1662

einordnung

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Removing lumbar adjustment device for the lumbar support

No. Procedure Removing front seat Removing covering for front backrest 1 Lumbar adjustment device without control module memory 2 Lumbar adjustment device 1 with control module memory

Instructions => Removing front seat

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). Unscrew fastening screw arrow and remove lumbar adjustment device 1 .

Removing lumbar adjustment device for the lumbar support

1663

einordnung

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Removing motor for the lumbar support

No. Procedure Instructions 3 Electrical plug connection 2 Pull off plug 2 on motor 3 for the lumbar support. 4 Motor 3 for the lumbar support Pull off air hose (white) and pull up and out from styrofoam.

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Removing electrical line for the lumbar

No. 5a

Procedure Electrical plug connection 5 for lumbar

5b

6 7

Electrical plug connection 6 for lumbar without control module for seat memory Electrical line 7 Observe lead route arrow and remove line. Electrical line Line runs parallel to the white air hose A . Lumbar adjustment device. Disconnect tie wrap, remove line. => Removing motor for the lumbar support

Instructions Pull off plug 5 arrow on control module seat memory 4 . Cut tie wrap on electric motor for the seat height adjustment using a pair of side cutters. Pull plug connection 6 apart below the seat.

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Removing lumbar support

No. Procedure Instructions 1 Air hose B, Pull off red B and blue C air hose on the lumbar adjustment device. C 7 Lumbar support Pull off felt arrow and pull lumbar support G up and and out of the backrest frame.

Removing motor for the lumbar support

1664

einordnung

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Installling lumbar adjustment device for the lumbar support

No. Procedure Instructions 1 Lumbar adjustment device 1 with Position lumbar adjustment device and secure on backrest control module memory frame with the fastening screw arrow . Tightening torque: 6 Nm (4.5 ftlb.) 2 Lumbar adjustment device without Connect air hose A (white), B (red), C (blue), control module memory electrical plug connection E, F on valve box. Plug in pressure switch D .

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Removing lumbar support

1665

einordnung

Installing motor for the lumbar support

No. 3 4

Procedure Motor for the lumbar support 3 Electrical plug connection 2

Instructions Plug in white air hose A on motor 3 and insert into styrofoam. Join plug 2 with electrical lead of motor.

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Installing electrical line for the lumbar

No. 5a

Procedure Electrical plug connection 5 with control module for seat memory

5b 6

Instructions Fasten line to motor with tie wrap for the rear seat adjustment and insert plug 5 on the control module 4 for the seat memory arrow . Electrical plug connection 6 without Join plug connection 6 below the seat. control module for seat memory Electrical line 7 Lay line behind motor for along the lumbar support. Observe routing under the lumbar support (airbag) and along the seat frame arrow . Electrical line Route the electrical line on the backrest frame parallel to the air hose A and fix with tie wrap.

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Installing lumbar support

No. Procedure 7 Lumbar support G 1 Air hose B, C Install covering for backrest. Installing front seat

Instructions Insert lumbar support G into the backrest frame from above and fix with felt strips arrow . Route red B and blue C air hose and fix loosely with tie wraps. Connect air hose B, C on the valve box.

=> Removing front seat

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Installing motor for the lumbar support

1666

einordnung

Tools

Item 1

Designation Multimeter

Special tool

Explanation: Gr. 2.5; Workshop Equipment Manual

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Test plan for the lumbar adjustment device

In the case of the complaint "lumbar support does not function", proceed according to the following work instruction. As the seat functions vary, the test plan principally complies with the seat version with seat memory adjustment. Work aids: Use wiring diagram and multimeter. => Tools Incorrect result Step 4 Step 4

Work instruction 1 Actuate switch positions on seat for lumbar support. Compressor for the lumbar is audible. 2 Actuate switch positions on seat for lumbar support. Valve block switches. 3 Take cover off backrest, check connections for air hose, lumbar support and valve block. 4

Correct result Step 2 Step 3

6 7

Check pressure switch and hose routing and replace if necessary. End Check fuse in the fuse box for the lumbar. Step 5 Replace fuse and perform function test. End Measure the battery voltage on plug X 16/ X 17 without > 11V Step 6 Check plug memory or terminals 30 and 31 on the memory SG (see connection wiring diagram) using a multimeter. and wiring. End When actuating the switch for the lumbar, clicking noises are Switch reacts. Step Step 8 audible from the control module for the seat memory. 7 Remove cover from backrest, check battery voltage of > 11V Replace Check wiring compressor plug connection using multimeter. compressor. and plug connection. End End Control module for the seat memory. Replace End

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Tools

1667

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

einordnung

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Removing switch for seat adjustment

No. Procedure Removing front seat. 1 Removing switch 2 from seat. 2 Control module 4 in connection with seat memory 3 Plug connection 6, 7, 8 without seat memory control module

Instructions => Removing front seat Unscrew fastening screws 1 . Pull switch 2 upward and remove to the front arrow . 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, natural, blue, black. Pull plugs below seat 6 , seat height adjuster, 7 lumbar, 8 backrest apart and disconnect tie wrap for the line.

Removing switch for seat adjustment

1669

einordnung 4 Lead route between seat cushion and seat frame. A Seat cushion B Switch C line Pull out the plugs one after the other through this opening.

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Installing switch for seat adjustment

No. Procedure 1 Line C of seat adjustment switch B 2 Line route 9

Instructions Push the plugs of line C one after the other through the opening below the seat cushion A . In connection with the seat memory control module, lay the line 9 above the electric motors and along the seat memory control 1670

Installing switch for seat adjustment

einordnung module 4 . Plug connection without control module for seat memory. Join plugs for 6 seat height adjustment, 7 lumbar, 8 backrest and fix line with tie wrap. Clip plugs on to eachother starting 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.) Insert the switch in direction of arrow against the seat and downward. Installing fastening screws 1 . => Removing front seat

Plug connection 6, 7, 8

Plug connection arrow on seat memory control module 4 .

Installing switch 2 . Installing front seat.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Installing switch for seat adjustment

1671

72 87 19 Removing and installing electric motor for the seat adjustment

Removing electric motor for seat adjustment Installing electric motor for seat adjustment Tools Test plan for the seat adjustment A = Electric motor for seat adjustment.

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Removing electric motor for seat adjustment

72 87 19 Removing and installing electric motor for the seat adjustment

1672

einordnung

No. Procedure Removing front seat 1 Lock nut 1 2 Fastening screws 2 3 Electric motor 3 4 Input shaft 4 5a Control module 6 in connection with seat memory 5b Plug connection 7 without seat memory control module. 6 Electric wire

Instructions => Removing front seat Unscrew. Unscrew. Unscrew. Remove and check for damage. Unscrew fastening screws 5 and fold control module 6 to front arrow . Press plugs together in direction of arrow and pull apart. Press out the crimp sockets from plug using the unlocking tool. => Tools Cut the tie wrap using side cutters, follow cable routing and pull off the plug 8 on the control module.

Removing electric motor for seat adjustment

1673

einordnung

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Installing electric motor for seat adjustment

No. Procedure 1 Input shaft 4 2 3 Electric motor 3 Fastening screws 2

Instructions Insert the input shaft 4 into the gear mount by twisting slightly. Push motor 3 onto the shaft and ensure that the square fits into the mount on the motor by twisting slightly. Position electric motor 3 with both fastening screws 2 and tighten screws. Tightening torque: 7 Nm (5 ftlb.)

Lock nut 1674

Installing electric motor for seat adjustment

einordnung Tighten. Tightening torque: 7 Nm (5 ftlb.) 5 Plug 8 in connection with seat Observe line routing and push in plug 8 on control module. memory control module Fix line routing with a tie wrap. 6a Control module 6 Engage control module 6 and screw into place with the fastening screws 5 . Tightening torque: 6 Nm (4.5 ftlb.) 6b Plug connection 7 without Push crimp sockets into the plug 7 until the sockets engage. seat memory control module. Attach plug 7 , observe line routing and fasten with tie wrap. Installing front seat => Removing front seat

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Tools

Item Designation 1 Pressout tool for the crimp sockets 2 Multimeter

Special tool No. 155

Explanation: Gr. 2.4; Workshop Equipment Manual Gr. 2.5; Workshop Equipment Manual

top of page

Test plan for the seat adjustment

In the case of complaint "seat adjustment does not function", proceed according to test plan. As the seat functions vary, the test plan principally complies with the seat version with seat memory adjustment. Work aids: Use wiring diagram and multimeter. => Tools Incorrect Work instruction Correct result result 1 Actuate switch on seat for seat adjustment, observe end Switch in control module Step 2 position. is audible. Step 3 2 Check fuse in the fuse box for the seat adjustment. Step 3 Replace fuse and perform function test. End 3 Measure the battery voltage on plug X 16/ X 17 without > 11V Step 4 Check plug memory or terminals 30 and 31 on the memory SG (see If a function is not audible connection wiring diagram) using a multimeter. under step 1, replace the and wiring. control module memory. End 4 Measure the voltage on the inserted plug for the seat > 4 V, when switching Replace adjustment (on control module memory or below the seat from front back, the switch. without memory) using a multimeter. Actuate the seat voltage switches from + to End adjuster switch with probe tip + on RE and with probe tip Step 5 on BK. 5 Remove motor and check input shaft. Tools 1675

einordnung Remove faulty part. End

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Test plan for the seat adjustment

1676

72 88 19 Removing and installing electric motor for the front seat height adjustment
Removing electric motor for front seat height 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.

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Removing electric motor for front seat height adjustment

72 88 19 Removing and installing electric motor for the front seat height adjustment

1677

einordnung

No. Procedure Removing front seat 1 Fastening screws 1 2 Electric motor 2 3 Input shaft 3 4a Control module 4 in connection with seat memory 4b Plug connection 6 without seat memory control module. 5 Electric line

Instructions => Removing front seat Unscrew. Remove. Remove and check for damage. Undo screws 5 . Detach control module 4 and fold it to the front. Pull out plugs of control module arrow . Press plugs 6 together and pull apart arrow . Press out the crimp sockets from plug using the unlocking tool => Tools Cut tie wrap on motor with side cutters and remove unit.

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Removing electric motor for front seat height adjustment

1678

einordnung

Installing electric motor for front seat height adjustment

No. Procedure Instructions 1 Input shaft 3 Insert the input shaft 3 into the gear mount by twisting slightly. 2 Electric motor Push electric motor 2 onto the input shaft 3 and ensure that the square fits 2 into the mount on the motor by twisting slightly. 3 Fastening Position electric motor 2 with both fastening screws 1 and tighten screws. screws 1 Tightening torque: 7 Nm (5.0 ftlb.) 4 Electric line Observe line routing. 5a Control module Insert plug on control module 4 arrow . Secure routed line with tie wrap. 4 Insert control module in the frame and screw in the fastening screws 5 . Tightening torque: 6 Nm (4.5 ftlb.) 5b Installing electric motor for front seat height adjustment 1679

einordnung Plug connection Push crimp sockets into the plug 6 until the sockets engage. Observe line 6 routing and secure with tie wrap. Installing front => Removing front seat seat

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Tools

Item Designation 1 Pressout tool for the crimp sockets 2 Multimeter

Special tool No. 155

Explanation: Gr. 2.4; Workshop Equipment Manual Gr. 2.5; Workshop Equipment Manual

top of page

Test plan for the front seat height adjustment

In the case of the complaint "seat height adjustment does not function", proceed according to test plan. As the seat functions vary, the test plan complies with the seat version with seat memory adjustment. Work aids: Use wiring diagram and multimeter => Tools Incorrect Correct result result Switch in control module Step 2 is audible Step 3 Step 3 Replace fuse and perform function test End 3 Measure the battery voltage on plug X 16/X 17 without > 11V Step 4 Check plug If a function is not connection memory or terminals 30 and 31 on the memory SG (see and wiring wiring diagram) using a multimeter. audible under step 1, replace the control End module memory. 4 Measure the voltage on the inserted plug for the seat height > 4 V, when switching Replace adjustment (on control module memory or below the seat from front back, the switch without memory) using a multimeter. Actuate the seat voltage switches from + End height adjuster switch with probe tip + on RE and with to Step 5 probe tip on BK. 5 Remove motor and check input shaft. Remove faulty part End

Work instruction 1 Actuate switch on seat for seat height adjustment, observe end position. 2 Check fuse in the fuse box for the seat height adjustment.

Tools

1680

einordnung 996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Test plan for the front seat height adjustment

1681

72 89 19 Removing and installing electric motor for the backrest adjustment

Removing and installing 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 device

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72 89 19 Removing and installing electric motor for the backrest adjustment

1682

einordnung

Removing and installing electric motor for the backrest adjustment

No.

2 3

Procedure Instructions Removing front seat => Removing front seat Removing covering for front backrest Clamping 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. Undoing fastening screws Unscrew fastening screw 3 on backrest motor 4 . 3 for backrest motor Input shaft 2 1683

Removing and installing electric motor for the backrest adjustment

einordnung Push input shaft 2 on the left side through using a screwdriver. Pull out input shaft 2 on the right side until the backrest motor can be removed. Remove backrest motor downward direction of arrow . Push both locking tabs of the plug connection outwards using a screwdriver and pull the plug 5 downward.

4 5 6

Input shaft 2 Backrest motor 4 Electrical plug connection 5

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Installing electric motor for backrest adjustment

No. Procedure

Instructions

Installing electric motor for backrest adjustment

1684

einordnung 1 2 3 4 Electrical plug connection 5 Backrest motor 4 Input shaft 2 Fastening backrest motor 4 Push plug 5 on to electric motor until it engages.

Insert backrest motor 4 from below direction of arrow . Insert input shaft from the right side as far as it will go arrow . Screw in fastening screw 3 . Ensure that the bushings arrow are seated correctly. Counter electric motor with your hand and tighten fastening screw 3 . Tightening torque: 6 Nm (4 ftlb.) Installing clamping Counter input shaft 2 on the right side and push clamping washer on to the washer left side of the input shaft 2 using a 12 mm socket for example. Installing covering for backrest Installing front seat => Removing front seat

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Routing of wiring harness for the backrest adjustment

1. A Plug on the control module for the memory seat adjustment. 2. B Plug on the backrest adjustment motor. 3. X Plug connection without control module for the memory seat adjustment. top of page

Tools

Item 1

Designation Multimeter

Special tool

Explanation: Gr. 2.5; Workshop Equipment Manual

top of page

Routing of wiring harness for the backrest adjustment

1685

einordnung

Test plan for the backrest adjustment device

In the case of the complaint "backrest adjustment does not function", proceed according to test plan. As the seat 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 1 Actuate switch positions on seat for backrest adjustment. Correct result Switch in the control module and electric motor function are audible. Step 3 Step 4 Incorrect result Step 2

2 Check fuse in the fuse box for the backrest adjustment. 3 Take cover partly of the backrest and check drive for backrest adjustment. 4 Measure the battery voltage on plug X 16/ X 17 without memory or terminals 30 and 31 on the memory SG (see wiring diagram) using a multimeter.

Replace fuse and perform function test. End

Repair End > 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 memory. > 4 V, when switching 5 Measure the voltage on the inserted plug for the backrest adjustment (on control module memory or from front back, the voltage changes from below the seat without memory) using a multimeter. Actuate the backrest adjuster switch with + to . Step 6 probe tip + on GY/BK and with probe tip on GY/GN. 6 Partly remove backrest cover, check wiring harness > 11V and battery voltage on the electric motor. On inserted plug, probe tip + on BU on BK. => Removing the backrest centre strip

If the battery voltage is only displayed briefly on the multimeter Step 6. Replace at 0 V switch. End

Replace switch. End

Replace motor for the backrest adjustment End

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Test plan for the backrest adjustment device

1686

72 92 19 Removing and installing electric motor for the rear seat height adjustment
Removing electric motor for rear seat height 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.

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Removing electric motor for rear seat height adjustment

72 92 19 Removing and installing electric motor for the rear seat height adjustment

1687

einordnung

No. Procedure Removing front seat 1 Fastening screws 1 2 Electric motor 2 3 Input shaft 3 4a Control module 5 in connection with seat memory 4b Plug connection 6 without seat memory control module.

Electric wire

Instructions => Removing front seat Unscrew. Remove in direction of arrow . Pull out shaft 3 and check for damage. Unscrew both fastening screws 4 and fold control module 5 to the front. Pull plug arrow 7 off the control module Press plugs 6 together in the direction of arrow and pull plug connection apart. Press the crimp sockets out of the plug using the unlocking tool. => Tools Cut the tie wrap with side cutters, follow the cable routing and remove completely.

Removing electric motor for rear seat height adjustment

1688

einordnung

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Installing electric motor for rear seat height adjustment

No. Procedure 1 Input shaft 3 2 3 Electric motor 2 Fastening screws 1

Line and plug connection 7

Instructions Insert the input shaft 3 into the gear mount arrow by twisting slightly. Push motor 2 onto the shaft and ensure that the square fits into the mount on the motor by twisting slightly. Position electric motor 2 with both fastening screws 1 and tighten screws. Tightening torque: 7 Nm (5 ftlb.) Observe line routing. 1689

Installing electric motor for rear seat height adjustment

einordnung 5a Seat memory control module 5 Insert plug arrow 7 on control module 5 . Fix line route with a tie wrap. Engage control module and tighten with both fastening screws 4 . Tightening torque: 6 Nm (4.5 ftlb.) 5b Plug connection 6 without seat Push crimp sockets into the plug 6 until the sockets engage. memory control module. Observe line route and secure with tie wrap. => Tools Installing front seat => Removing front seat

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Tools

Item Designation 1 Pressout tool for the crimp sockets 2 Multimeter

Special tool No. 155

Explanation: Gr. 2.4; Workshop Equipment Manual Gr. 2.5; Workshop Equipment Manual

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Test plan for the rear seat height adjustment

In the case of the complaint "seat height adjustment does not function", proceed according to test plan. As the seat functions vary, the test plan principally complies with the seat version with seat memory adjustment. Work aids: Use wiring diagram and multimeter. => Tools Incorrect Work instruction Correct result result 1 Actuate switch on seat for seat height adjustment, observe Switch in control module Step 2 end position. is audible. Step 3 2 Check fuse in the fuse box for the seat height adjustment. Step 3 Replace fuse and perform function test. End Check plug 3 Measure the battery voltage on plug X 16/ X 17 without > 11V Step 4 memory or terminals 30 and 31 on the memory SG (see If a function is not connection wiring diagram) using a multimeter. audible under step 1, and wiring. replace the control End module memory. 4 Measure the voltage on the inserted plug for the seat height > 4 V, when switching Replace adjustment (on control module memory or below the seat from front back, the switch. without memory) using a multimeter. Actuate the seat voltage changes from + to End height adjuster switch with probe tip + on RE and with . Step 5 probe tip on BK. 5 Remove motor and check input shaft. Remove faulty part. End Tools 1690

einordnung

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Test plan for the rear seat height adjustment

1691

74 13 55 Replacing cover for front seat cushion

Removing cover for the front seat Installing cover for the seat cushion. Tools and materials

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Removing cover for the front seat

74 13 55 Replacing cover for front seat cushion

1692

einordnung

No. Procedure Removing front cushion carrier 1 Removing seat cover of cushion carrier 2 3 Destroying plastic clips Cover for the seat cushion.

Instructions => Removing front cushion carrier Detach rear retaining rail 1 from the cushion carrier. Undo right and left side cushion clips 2 . Pull off the pushon bead 3 surrounding the seat cover of the cushion carrier. Destroy plastic clips 4 with a screwdriver. Remove the seat cushion with the cushion carrier foam part. Cut open the metal clips with side cutters 5 . Separate the cover for the seat cushion from the foam part.

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Removing cover for the front seat

1693

einordnung

Installing cover for the seat cushion.

No. 1

Procedure Mounting the seat cover on to the foam part (seat cushion)

Instructions Position seat cover covering strips C with an integrated metal strut A on the centre, left and right seat centre strip and on the provided cutouts on the foam 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 Mounting the seat cover Note: on to the cushion carrier The plastic clips 4 should always be replaced. Insert plastic clips 4 onto the left and right covering strips E and position on the provided cutouts on the foam part and clip onto 1694

Installing cover for the seat cushion.

einordnung the cushion carrier. Fit the seat cover over the foam part so that it is free from wrinkles. Push the pushon bead 3 surrounding the seat cover onto the cushion carrier. Engage the rear retaining rail 1 in the cushion carrier. Clip the seat cover at the right and left onto the cushion carrier 2 . => Tools and materials => Installing front cushion carrier

Fitting seat cover onto the cushion carrier

Installing cushion carrier

CAUTION Danger of material damage if excessive heat is applied! If creases form, only short partial warming with the hotair gun is permissible. Always observe the hotair temperature of approx. 50 degrees Celsius (122 Fahrenheit).

No.

Procedure Instructions Remedying creases in the backrest If creases form in the areas of the backrest cover, heat cover them partially with the hotair gun.

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Tools and materials

Item 1 2 3

Designation of the special tool Cushion clip pliers and cushion clips Nr. 130 Cushion clips Pneumatic staple gun Nr. 163

Explanation Gr. 2.4; Workshop Equipment Manual Spare part Gr 8; Parts Catalogue Gr. 2.4; Workshop Equipment Manual

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Tools and materials

1695

74 19 19 Removing and installing centre backrest strip

Removing the backrest centre strip Installing the backrest centre strip

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Removing the backrest centre strip

74 19 19 Removing and installing centre backrest strip

1696

einordnung

No. 1

Procedure Detaching covering strip from the backrest shell and disconnect electrical plug connection.

Unclipping the backrest centre strip

Instructions Press locking tabs of the backrest seat heating A and disconnect downward B . Unclip the electrical line 2 from the metal clips 3 along the seat frame. Pull backrest centre strip 1 downwards and out of the backrest shell4 . Insert your hand into the top of the backrest covering and lift outward arrow . Information: Do not lift the backrest covering too firmly outwards as otherwise the plastic clips can be destroyed. Press the bead 6 out of the plastic clips 5 using a screwdriver.

Removing the backrest centre strip

1697

einordnung top of page

Installing the backrest centre strip

No. Procedure 1 Clipping in the backrest centre strip at the top 2 Attaching the backrest centre strip at the bottom, inserting electrical plug connection

Instructions Press the bead 6 into the plastic clips 5 . Attach backrest centre strip 1 to the bottom of the backrest shell 4 . Plug in backrest seat heating. Clip electrical line 2 into the metal clips 3 along the seat frame.

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841 Installing the backrest centre strip 1698

74 19 55 Replacing covering for backrest centre strip

Removing covering for backrest centre strip Installing covering for backrest centre strip Tools and materials

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Removing covering for backrest centre strip

74 19 55 Replacing covering for backrest centre strip

1699

einordnung

No.

Procedure Removing backrest centre strip Pulling off fabric tape strips Cutting through the cushion clips

Instructions => Removing the backrest centre strip Pull of the felt strips 2 from the plastic frame 4 . Detach the covering for the backrest centre strip 1 from all sides of the plastic frame 4 . Cut through the cushion clips 3 using side cutters. Detach the bead for the backrest centre strip 5 and the plastic frame 4 from the centre strip foam part 6 .

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Removing covering for backrest centre strip

1700

einordnung

Installing covering for backrest centre strip

No. 1

Procedure Placing the cushion clips

Instructions Position backrest centre strip 6 and plastic frame 4 onto the centre strip foam part. Connect the covering strips 5 to the plastic frame 4 using the cushion clip pliers A and the cushion clips 3 . Engaging the backrest Attach the covering for the backrest centre strip 1 to all sides of the centre strip plastic frame 4 . At the connecting webs of the plastic frame 4 , affix a felt strip 2 , approx. 25mm wide, across the entire width of the plastic frame. => Tools and materials Installing the backrest => Installing the backrest centre strip 1701

Installing covering for backrest centre strip

einordnung centre strip

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Tools and materials

Item 1 2 3

Designation of the special tool Cushion clip pliers and cushion clips Nr. 130 Cushion clips Felt strips

Explanation Gr. 2.4; Workshop Equipment Manual Spare part Gr 8; Parts Catalogue Spare part Gr 8; Parts Catalogue (Seat)

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Tools and materials

1702

74 27 19 Removing and installing control module for seat heating

Removing 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

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74 27 19 Removing and installing control module for seat heating

1703

einordnung

Removing and installing control module for seat heating

The control module for the seat is located on the right side for the driver's seat and on the left side for the passenger's seat. A Backrest plug connection. B Seat cushion plug connection. C Plug connection for seat heating control module D Expanding rivet.

1. Removing control module for seat heating => Removing front seat a. Press the pin into the expanding rivet 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 control module onto the plug C . b. Fix the control module and holder with the expanding rivet D and press the pin in the rivet. top of page

Seat heating line route

A Plug connection for backrest heating element a Press plug for backrest heating element together arrow and pull from the plug connection A . B Plug connection for seat heating element Removing and installing control module for seat heating 1704

einordnung b Push plug for seat heating element onto B until the plug connection engages. C Base for seat heating control module. D Connection for seat heating wiring harness for the central plug. E Power supply, plug for central plug. top of page

Central plug
A Coding pin: In the Boxster in opening 2, in the 911 Carrera and 911 Turbo in opening 5. Pin BR opening 6, pin RE/VI opening 3. B Slide in lockin position.

1. Removing coding pin and pin => Removing 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 using pressout tool. => Tools 3. Removing coding pin and pin a. Insert coding pin A and pin into the flat connector until it engages. b. Insert fuse 2 in direction of arrow until it engages. c. For seat installation: Insert counter plug into vehicle and push in slide B . top of page

Removing and installing pin housing for seat heating and belt buckle
C Seat heating pin housing D Belt buckle pin housing

Seat heating line route

1705

einordnung

1. Removing pin housing for seat heating and belt buckle => Removing front seat a. Cut tie wrap on rear side of central plug with side cutters. b. Push fuse 2 away from flat connector in direction of arrow 2 . c. Pin housing: Push out the belt buckle D and seat heating C in direction of arrow 1 . 3. Installing pin housing for seat heating and belt buckle a. First insert the seat heating pin housing C , then the belt buckle D into the flat connector. b. Push fuse 2 onto the flat connector. c. Observe the line route and secure with tie wraps on the rear side of the flat connector. top of page

Tools

Item Designation 1 Pressout tool for the crimp sockets 1 Multimeter

Special tool No. 155

Explanation Gr. 2.4; Workshop Equipment Manual Gr. 2.5; Workshop Equipment Manual

top of page

Test plan for the seat heating

In the case of the complaint "seat heating does not function", proceed according to the following work instruction. Work aids: Use wiring diagram and multimeter. => Tools Work instruction Correct result 1 Actuate seat heating switch, LED lights up in Step 2 the switch 2 => Removing front seat > 11V Step 3 Switch on ignition, measure battery voltage on the plug bracket for the seat heating Incorrect result Step 5 Check plug connection and wiring. End 1706

Removing and installing pin housing for seat heating and beltbuckle

einordnung control module using a multimeter. Pin 5 and pin 9. 3 Perform heat element resistance test for the backrest and seat area using a multimeter. Pull the plug off the seat heating control module and check the resistance on the plug bracket RE/WT pin 3 and BR pin 9. 4 Seat heating control module 5 Check fuse in the fuse box for the seat heating.

Depending on temperature, approx 2 Step 4

Check resistance test on backrest and seat area heating elements via the respective connecting plug (approx. 1 ) and replace defect heating element . End

Replace fuse and perform function test. End 6 Check seat heating switch lines for continuity Replace switch for the seat heating. using a multimeter. End

replace. End Step 6

996420, 996421, 996450, 996451, 996430, 996431, 996840, 996841

Test plan for the seat heating

1707

90 25 19 Removing and installing instrument cluster

Removing instrument cluster Installing instrument cluster Coding the instrument cluster top of page

Removing instrument cluster

Note If the vehicle is equipped with a handsfree telephone, disconnect the microphone plug connection instead of the dummy plug! 1. Disconnect the battery and cover terminal or battery. 2. Switch on the hazard warning light switch (button comes out). On the sides of the button, there are small openings that project beyond the dashboard 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 dashboard insert by two locking hooks. 5. Press the right locking hook towards the switch, grip the button holder with a pair of pliers and pull out the switch towards the front. 6. Undo 5.0 x 30 Torx screw on the dashboard insert.

7. Pull off plug on the left side and undo the 5.0 x 30 Torx screw. 8. Unclip the dashboard insert and disconnect the electrical plug connections. 9. Detach the instrument cluster from the dashboard insert and remove it. top of page 90 25 19 Removing and installing instrument cluster 1708

einordnung

Installing instrument cluster

1. Engage electrical plug connections and fasten the dashboard insert on 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. Connect the battery and perform a function test. If a new instrument cluster has been installed, it must be coded.

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Coding the instrument cluster

Note As of model year '01, the tolerance of the speed display has been restricted. This was achieved by changing the software ("Knumber") on the instrument cluster and PCM control module. The "Knumber" varies depending on vehicle type and country equipment. The reason is as follows: different displays of the total mileage and the fuel consumption/average consumption in the instrument cluster and the PCM control module. Therefore, in the case of repairs, the Knumber in the instrument 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 for the total mileage and fuel consumption/average consumption will be displayed on the instrument cluster and the PCM control module when in driving mode. PROCEDURE for coding the instrument cluster: 1. Connect the PST2 to the diagnostic socket; switch on the PST2 and the ignition. 2. In the menu "Control units", select Instrument cluster 3. In the function selection, select Coding . 4. Select menu item Country coding . 5. Select the respective country and code with F8 key. The other menu items are described in the Diagnosis Manual, folder 0, 9025 Control module replacement, instrument cluster . Note In general, the Knumber is adjusted when coding the instrument cluster. However, this point must be checked again when coding is complete, as described under PROCEDURE for changing the "Knumber" in the instrument cluster (as of PST2 software 13.0): Installing instrument cluster 1709

einordnung PROCEDURE for changing the "Knumber" in the instrument cluster (as of PST2 software 13.0): 6. In the function selection, select Synchronise Knumber . 7. Start the function using the key >> . 8. After the function has been successfully performed in the instrument cluster, the message Knumber synchronised or the message Knumber updated appears in the Tester display. If the Knumber is not updated, a connection to the PCM is set up automatically. The message Connecting to PCM appears. 9. Then the message Function successfully completed appears. 10. Return to the Start menu with the button "ESC", switch off the PST2 and disconnect from the diagnostic socket.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Coding the instrument cluster

1710

91 10 19 Removing and installing display and operator control unit (PCM)

Note Removing display and operator control unit (PCM) Installing display and operator control unit (PCM) Note In the instrument cluster of the 911 Turbo, the tolerance of the speed display has been restricted. This was achieved by changing the software ("Knumber") on the instrument cluster and PCM control module. The "Knumber" varies depending on vehicle type and country equipment. The reason is as follows: different displays of the total mileage and the fuel consumption/average consumption in the instrument cluster and the PCM control module. Therefore, in the case of repairs, the Knumber in the PCM control module must be corrected with the Porsche System Tester 2 (PST2) after the installation of a new PCM control module or a new instrument cluster in vehicles as of model year '01. > If this correction is not carried out, conflicting values for the total mileage and fuel consumption/average consumption will be displayed on the instrument cluster and the PCM control module when in driving mode. PROCEDURE for changing the "Knumber" 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 is ready, select vehicle type and start the automatic control module search with the key >> . 3. In the menu "Control units", select Instrument cluster 4. In the function selection, select Synchronise Knumber . 5. Start the function using the key >> . 6. After the function has been successfully performed in the instrument cluster, the message Knumber synchronised or the message Knumber updated appears in the Tester display. Subsequently, it is automatically connected to the PCM. The message Connecting to PCM appears. 7. After the function has been successfully performed in the PCM, the message Knumber synchronised or the message Knumber updated appears in the Tester display. Subsequently, it is automatically reconnected to the instrument cluster. The message Connecting to instrument cluster appears. 8. Then the message Function successfully completed appears. 9. Return to the Start menu with the button "ESC", switch off the PST2 and disconnect from the diagnostic socket. top of page

91 10 19 Removing and installing display and operator control unit (PCM)

1711

einordnung

Removing display and operator control unit (PCM)

1. Unclip the switch covers from below and let them dangle from the electric leads.

2. Press together both spring clamps on the display and operator control unit and carefully pull out. 3. Disconnect electrical plug connections from the display and operator control unit. top of page

Installing 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 plug connections and carefully lay the electrical leads (do not pinch). 2. Connect and switch on the Porsche System Tester 2.

Connecting and switching on the Porsche System Tester 2

1. Switch ignition on. 2. Switch on PCM by pressing the volume control (display remains dark). Removing display and operator control unit (PCM) 1712

einordnung 3. Establish communication with the Porsche System Tester 2 and select PCM. 4. Select Modify coding. 5. Select PCM active. 6. Confirm PCM active with the F8 key.

Device code input

The display and operator control unit is protected against theft by 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 operator control unit first! Only the navigation code has to be input again if the navigation unit is exchanged!

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Connecting and switching on the Porsche System Tester 2

1713

91 10 19 Removing and installing display and operator control unit (PCM 2) as of MY 2003
Removing display and operator control unit (PCM 2) Installing display and operator control unit (PCM 2) Teaching display and operator control unit (PCM 2) top of page

Removing display and operator control unit (PCM 2)

Note If the PCM is replaced by a new or a different PCM, read out the data with the Porsche System Tester before removal. => Teaching display and operator 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 cover from below using a plastic spatula and disconnect electrical plug connections.

2. Insert a hexagonsocket wrench sideways into the screw connection of the PCM detent hooks. 3. Close the detents (2 each side) with the hexagonsocket wrench A and carefully pull out the PCM. 4. For reinstallation, open the detents with the hexagonsocket wrench B . Note 91 10 19 Removing and installing display and operator control unit (PCM 2) as of MY 2003 1714

einordnung The number of plug connections will vary, depending on the I No. (CD changer, Bose, amplifier). The variant without additional audio components (external Most control units) has a jumper (output to input) connected to the optical waveguide plug.

5. Unlock and pull off antenna plugs A, E, F . 6. Unlock and disconnect the 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 PCM and installed in the new PCM. If the old PCM is being reinstalled, then begin at Step 6.

1. Before the new PCM is installed, unlock and disconnect the protective plug A for the optical waveguide. 2. Unclip the cover on the new and old PCM.

Removing display and operator control unit (PCM 2)

1715

einordnung 3. With the PCM removed, carefully lever out the navigation module using a screwdriver.

4. Insert the navigation module into the PCM to be installed.

5. Position the cover and press into place.

6. Push on the electrical plug connections for the display and operator control unit in the sequence 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 hexagonsocket wrench if necessary. Note Before sliding the PCM into the installation slot, make sure that the electrical leads are not trapped by the PCM or damaged. 8. Push the navigation unit into the installation slot until the locks engage on the PCM housing. Installing display and operator control unit (PCM 2) 1716

einordnung

9. Connect the electrical plug connections to the switch cover. 10. Position switch cover and press in until it is felt to engage. Note After installation of a new display and operator control unit, the system must be activated with the Porsche System Tester! 11. Connect and switch on the Porsche System Tester 2. top of page

Teaching display and operator control unit (PCM 2)

Note If a new PCM is to be installed in a vehicle, the PCM2/CDR23 code specified in IPAS must be used. You can get the codes from IPAS or from your importer by specifying the vehicle identification number. During coding, the power supply for the Porsche System Tester should be guaranteed. 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 instructions that must be followed. A discrepancy may arise with later software versions (from 20.0). The procedure described here has been structured generally; different text or additions may appear in the Porsche System Tester. 1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Press >> to continue. 2. Select vehicle type using the cursor keys. 3. Using the >> key, move from the vehicle type to the list of control modules. 4. Select PCM2 with the cursor keys and press the >> key. 5. In the PCM2 menu, move to PCM2 MMI using the cursor keys and press the >> key.

Teaching display and operator control unit (PCM 2)

1717

einordnung 6. Select Coding with the cursor keys and press the >> key. 7. If possible, select the coding, read it out and note it down if necessary. 8. Switch off ignition and replace the PCM2. => Removing display and operator control unit (PCM 2) 9. Switch on ignition. After replacement of the PCM2, go back to the PCM2 MMI menu using the >> key. 10. Select PCM2 code in the Coding menu and press >> to continue. 11. Enter the IPAS PCM2 code and code it with the F8 key. 12. Follow the instructions on the Tester. Note In the case of a new PCM2, continue with Step 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 Knumber, standard and code with the F8 key. Knumber, standard: Turbo RoW RoW Turbo USA USA 15. Select Knumber, real and code with the F8 key. Knumber, real: Turbo RoW 3900 RoW 3967 Turbo USA 3984 USA 4010 16. Select Country coding , choose the relevant country and code with the F8 key. 17. Select Vehicle type vehicle coding and code with the F8 key. Vehicle type vehicle coding Not coded 911 (996) Boxster Cayenne 18. Select Vehicle version vehicle coding and code with the F8 key. Vehicle version vehicle coding Teaching display and operator control unit (PCM 2) 1718 3900 3967 3984 4010

einordnung Not coded Coup Cabrio Targa 19. Select Air conditioning and code with the F8 key. Air conditioning Without air conditioning With air conditioning 20. Select Units and code with the F8 key. Units RoW (C, litre, km) UK (C, gallon, mph) USA (F, gallon, mph) 21. Select Time zone from 0 to 0.5 and code with the F8 key. 22. Select Right/lefthand drive vehicle coding and code with the F8 key. Right/lefthand drive vehicle coding Lefthand drive Righthand drive 23. Select Date , Time Summer/winter time , Display format , Timeout , Traffic broadcast loudspeaker boost , GAL and so on and code with the F8 key. 24. Switch to the MOST actual installed components list . Note The installed components that 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 components list . 25. Switch to MOST required installed components list . 26. If 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. 27. Read out the fault memory and erase it if necessary. 28. Exit the PCM2 MMI menu by pressing << and switch to the PCM2 GW menu. In the PCM2 GW menu: 29. Select the MOST switch in the Coding menu using the >> key and code with the F8 key. The MOST switch is open if external control modules are installed (e.g. CD changer, amplifier). See Vehicle equipment.

Teaching display and operator control unit (PCM 2)

1719

einordnung MOST switch Open (default) Closed (internal ring) 30. Select Production mode and press >> . 31. Select Production mode Off and code with the F8 key. 32. Select Tuner parameters menu and code with the F8 key. Tuner parameters Europe USA South America Australia Asia (South) Africa Japan 33. Exit the PCM2 menu using the << key. 34. Read out the fault memory and erase it if necessary. 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. Wait until the alarm system LED flashes normally . Unlock the vehicle and switch on the PCM2 again. If the PCM2 still does not switch on after this procedure, proceed in accordance with the Technical Manual. 0, 9101 PCM/CDR23

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Teaching display and operator control unit (PCM 2)

1720

91 20 02 Checking complaints about car radio system

Malfunctions in radio system Reduced sound quality in one or more loudspeakers Remedying problems with the amplifier Interference noises Electromagnetic compatibility (EMC) Troubleshooting Tools top of page

Malfunctions in radio system

1. Check error and customer complaint. 2. Switch ignition off and remove ignition key. 3. Remove radio fuses (ignition and memory). 4. Wait approx. 3 minutes until all components are free of tension. 5. Insert fuses again. 6. Check error and customer complaint again. Work instruction 1 Check error and customer complaint again. Radio function OK? No Does radio have a CD player or a magnetictape drive? Yes Check signal lead No Go to Step 2 Does radio have a display? If an audio signal can be heard, connect Step 6 a functional radio Step 3 If no audio signal can be heard Step 5 Does the system now function Replace radio => Interference perfectly? End noises End Repair wiring harness or plug Connect 7. Check all radio connections. functional radio connection 8. Check voltage at the connections End Step 3 battery and ignition . 9. Check ground connection of radio. Radio function OK? Connect 10. Disconnect audio connections 13. Check connection between the functional radio from radio. radio and the amplifier with a Step 3 multimeter. 11. At maximum volume setting, measure the alternating voltage at 14. 1721 Yes Check battery charging condition and battery cables for perfect contacts. If the problem persists, contact radio manufacturer End

91 20 02 Checking complaints about car radio system

einordnung the outputs. 12. Is the voltage between 8.4 and 11.0V? Radio function OK? Check the audio connections (+) and () for short circuits or ground connections. 15. Check polarity of the entire wiring. 16. Repair any detected damage. End Repair the cable connection and check Step 4 the system End

Is a short circuit present?

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Reduced sound quality in one or more loudspeakers

Note Reduced sound quality may be accompanied by a humming noise. 1. Switch on the system and change the fader and balance setting on the radio. 2. Check the fault status. 3. Find out on which channels the problem occurs. Work instruction 1 Switch the radio between FM, AM, cassette and CD (depending on the available components). Does the problem occur in all program sources? 2 Is a humming noise audible on one channel? Yes 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. No If the problem only occurs in FM or AM radio reception, check the reception. If the problem persists, replace the radio or CD player End Step 3

Check the polarity of the cable connection between the radio and the Bose amplifier. Remedy any possible problems. If the fault has been remedied End. If the fault is still present Step 3 3 Connect a functional radio/CD Replace radio/CD player Connect a functional player. Problem remedied? End amplifier End 4 Carry out a comparative test with Involve the customer in the Step 3 a functional system. comparative test. System behaviour identical? Customer satisfied End. Customer not satisfied, consult Porsche After Sales.

top of page Malfunctions in radio system 1722

einordnung

Remedying problems with the amplifier

Work instruction 1 Check amplifier connections for damage and then connect a functional amplifier. Interference noises still present? 2 Are the interference noises still present?

No If the interference noises only come from one loudspeaker, insert a functional loudspeaker Step 2 Replace loudspeaker Lay the cable supply End lines again, making sure that there is adequate clearance to other cables and electrical components; if necessary, reconnect the loudspeaker connection. Also, twist the loudspeaker leads together to minimise the interference noises Step 3 Are the interference noises still 1. Check the audio cables between the End present? radio and the amplifier for free points, short circuits and high resistance. 2. Check all cable connections for bent or loose connections, corrosion or other damage. Step 4

Yes Replace amplifier End

Repair cable connections. Are the interference noises still present?

7. Localise the battery connection (+) of the

3. Localise the ground connection for the amplifier. 4. Disconnect the ground lead on the amplifier side. 5. Reconnect the ground connection at an appropriate point. 6. Measure the functionality of the ground connection with a multimeter beween the negative terminal of the battery and the relevant ground point (potential difference). Step 5 End

No: End

=> Interference noises

Remedying problems with the amplifier

1723

einordnung amplifier. 8. Disconnect the lead on the amplifier side. 9. Insert an interference filter. 10. The negative terminal of the interference filter should be installed facing towards the amplifier. Interference noises remedied?

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Interference noises
Note This procedure is designed to help you find out how the interference noise has entered the system. In the following subchapters, the various interference noises are differentiated. The battery must be fully charged. No charging unit may be connected.

Work instruction 1 Does the interference noise complained about by the customer really exist? 2 Can the interference noise be heard in all the loudspeakers?

Disconnect the antenna from the radio and observe the interference noise. Does the interference noise change or disappear? Does the interference noise change?

Yes Disconnect all electrical connections to retrofitted accessories, such as twoway radios, mobile telephones, radar detectors, etc. Step 2 Slowly pull the receiver component(s) out of the holder and observe the noise. Does the interference noise change or disappear in the process? Yes Step 4 No Step 3 => Interference noise due to antenna

No End

=> Interference noises, checking cable connections

=> Interference noises due to all looudspeakers

=> Interference noises due to alternator => Interference noises due to engine => Interference noises due to power supply

=> Interference noises due to all looudspeakers

Interference noises

1724

einordnung

Interference noises, checking cable connections

Note Procedure for interference noises which enter the system via the audio connections.

Work instruction Yes 1 1. As an experiment with the radio switched 3. Check the plug off, exchange the loudspeaker cables of the contacts of the loudspeaker involved in the complaint with connecting cable on those of a fully functional loudspeaker at the the amplifier and amplifier output. the loudspeaker. 2. Switch the radio on. 4. Repair or clean any defective connections. Is the loudspeaker involved in the complaint now free of interference noise? Noise no longer present End Noise still present Step 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?

No As an experiment, use a new cable from the amplifier to the loudspeaker. Noise disappeared: insert new audio cables and lay them separately from each other. Noise no longer present End Noise still present Step 4 7. Check the plug contacts of Install a the cable on the amplifier functional amplifier and the radio. End 8. Repair or clean any defective connections.

9. Check the audio wiring harness for a good ground connection. 10. Measure with a multimeter at the negative terminal of the battery. Repair the wiring harness. Noise still present?

Noise disappeared End Noise still present Step 3 As an experiment, insert new End leads between the radio and the amplifier. Noise still present: install new amplifier and radio. Noise remedied: install new audio cables End As an experiment, install first End a functional amplifier and then a functional radio End

11. Check the plug contacts of the connecting cable on the loudspeaker. 12. Repair or clean any defective connections. Noise still present?

Interference noises, checking cable connections

1725

einordnung

Interference noises due to alternator

Work instruction 1 Connect a plug connection to the alternator. Start engine. Minimise the volume at the radio. Switch on high loads and change the engine speed with brief accelerations.

Yes 1. Check the connections of the battery. Make sure that all connections are seated properly, are tightened and are not corroded. 2. Check the ground connection of the engine, the alternator and the battery's negative terminal and measure with a multimeter at the negative terminal of the battery and the respective ground point (potential difference). 3. Make sure that all ground connections are fully tightened and clean. 4. Check the connections of the alternator.

No End

Are the interference noises still present? If necessary: clean and repair the connections and, if necessary, install a condenser End

Interference noises due to engine

The following points should be checked first: Note Make sure that the battery connections are seated properly and that the ground connection is guaranteed. Check whether the ignition coils are loose or defective. Check the plug connections and supply lines for the ignition coils for damage. Check the ground connections on the engine. Check whether the correct spark plugs have been installed and that the electrode gap is OK.

Work instruction 1 Does the interference noise change with the engine speed? This work instruction must not be carried out on public roads.

Yes Drive the vehicle in 1st or 2nd gear at a speed of 3,000 rpm (with audible noise), then suddenly remove the pressure from the accelerator. Noise present: 1.

No Does the interference noise only occur when the car is driving? Step 2 1726

Interference noises due to alternator

einordnung Check the lead connections to the injection nozzle. Check in particular for loose or corroded connections. 2. Check resistance of the injection nozzles. R = 12 Ohm +/ 0.6 Ohm. Noise no longer present End Noise present Check the points listed above under Note once more. 2 3. Check for faults caused by vehicle components which have an influence on the speed. 4. Disconnect the component from the power supply and test again. Noise still present? 5. Check the wiring of the components for unfavourable positioning and loose or corroded connections. 6. Lay the cables again or repair. 7. As an experiment, insert a functional component and replace, if necessary. Check the radio reception End Does the noise not occur when the car is driving? Step 3

End As an experiment, insert a functional 8. Check the wiring of the component and replace, if necessary components for unfavourable positioning and loose or corroded End connections. 9. Lay the leads again or repair. Noise still present?

End

Interference noise due to antenna

Note Follow this test routine if the interference noises come from the antenna. As an experiment, it is worth making a comparison by inserting a rod antenna.

Work instruction 1 1. Clean all connections.

Yes

5. Check all antenna mountings for good ground connections with the negative 2. Connect a ground strap to the terminal of the battery. antenna plug. 3. Connect the other end of the ground 6. Check all hardware mountings for firm seating and clean ground connections. strap to a suitable point on the car Noise present Step 2 body. Noise not present End 4. Check the ground connection

No End

Interference noises due to engine

1727

einordnung with a multimeter at the negative terminal of the battery. Interference noise still present? 2 => Interference noises due to power supply 7. Cut the ground cable to the radio End approx. 30 cm from the device. 8. Make a ground connection directly to the radio housing. 9. Connect the 30cmlong end of the ground cable to the radio housing. 10. Connect the new ground connection to a suitable point on the car body. 11. Check the ground connection with a multimeter at the negative terminal of the battery. Interference noise still present? Replace defective components End

Interference noises due to power supply

Note Use this test routine for interference noises which originate from the vehicle electrics.

Work instruction 1 1. Temporarily disconnect the connections to terminals 30, 15 and ground on the radio. 2. Connect terminals 30, 15 and ground temporarily via a separate lead. 3. Connect the other end of this lead to the vehicle battery. Interference noise still present?

Yes No The interference noise is triggered 4. Reconnect the via the radio original cable Step 2 connections to the radio. 5. Temporarily disconnect the connections to terminals 30, 15 and ground on the amplifier. 6. Connect terminals 30, 15 and ground temporarily via a different lead. 1728

Interference noise due to antenna

einordnung 7. Connect the other end of this lead to the vehicle battery. If the noise is still present, the amplifier is the cause of the fault Step 2 Noise no longer present Step 3 Step 3

Connect the other end of the improvised lead connection at the connection for terminals 30, 15 to the fuse of the radio or the amplifier. Interference noise still present?

Check whether the noise occurs when a switch or an accessory component is switched on.

Lay terminals 30, 15 and the ground lead differently or insert a new lead and lay the new lead at a diastance from all other current circuits. Noise still present: Step 3 Noise no longer present: End Localise the cause for the interference noise in the retrofitted accessories and remedy End

Briefly disconnect the connections on the => Interference noises due to alternator and start the engine. alternator Noise still present? 8. Find out which circuit is causing the Step 6 interference noises by removing individual fuses, relays and switches. 9. Insert all removed fuses, relays and switches again. 10. Disconnect all components in turn which are connected to the affected circuit, until the interference noise has disappeared. 11. Replace defective components. Noise still present? Step 7 12. Lay all wiring harnesses from the defective component and the connecting leads with suitable clearance.

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 => Interference noises due to engine End

End

Interference noises due to power supply

1729

einordnung 13. Remove any audio cables which are causing the problem from the wiring harness. Noise still present? 7 14. If the suspected component uses the Step 8 same ground connection as a component of the audio system, establish a problemfree ground connection. 15. If ground connections are running via the same wiring harness, separate them from each other. 16. Wrap the terminal 30 and 15 lead of the suspected component with a film or a metal tape and connect the lead to a ground connection. 17. Check the ground connection with an ohmmeter at the negative terminal of the battery. Noise still present? End 18. Find 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 looudspeakers

Note The loudspeaker leads are twisted together as standard.

Work instruction 1 Check all connections to the amplifier or the radio. Take particular note of loose or bent pins, corrosion or other damage. Damage present? 2 1. Localise the ground connection cable of the amplifier. 2. Disconnect the ground connection cable on the amplifier side. 3. Lay the ground connection cable separately

Yes Repair the lead connection. Noise still present? Step 2. Noise remedied? End Disconnect all amplifiers but one from the power supply Step 3

No Step 2

End

Interference noises due to all looudspeakers

1730

einordnung and connect. 4. Check the ground connection with an ohmmeter at the negative terminal of the battery. Noise still present? 3 5. Check all connections of the amplifier. 6. As an experiment, insert a functional amplifier in place of the suspected defective one. Step 4 Replace amplifier End

Noise still present? Disconnect the audio inputs from the amplifier, Step 5 whereby the connections for terminals 30, 15 and ground must be maintained. Noise still present?

If the amplifier is switched on via a relay, remove 7. Localise the battery the relay and connect the amplifier directly to the connecting cable of the power supply. amplifier. Noise still present? 8. Cut this cable. 9. Install an interference filter at the cut point. End

Repair the audio connecting cable, lay it again or replace End Replace the closing relay of the amplifier End

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Electromagnetic compatibility (EMC) Troubleshooting

Note Check the complaint to make sure that the symptoms really exist.

Work instruction 1 Is the vehicle equipped with retrofitted accessories (radar detector, twoway radio, mobile telephone)?

Yes No Remove the accessories / Collect information take them out of operation about the complaint: Step 2 Which reception ranges are affected? With engine switched on or off?

Electromagnetic compatibility (EMC) Troubleshooting

1731

einordnung Constantly or occasionally? Step 3 Correct installation End End

2 Were the accessories installed according to the manufacturer's instructions? 3 Circle the EMC elements: Trigger Receiver 1. Check the suspected components. 2. Replace with functioning components. Complaint still present? 4 Check the wiring between the trigger and the receiver: Ground connection Plug connections Positioning of wiring harness Complaint still present?

Step 3 Step 4

Consult Porsche After Sales End

Repair lead connection End

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Tools

Item 1

Designation Multimeter

Special tool

Explanation: Gr. 2.5; Workshop Equipment Manual

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Tools

1732

91 24 19 Removing and installing the car radio as of MY 2003

Tools Removing the car radio Installing the car radio Teaching the car radio top of page

Tools

Removal tool

Item Designation Source Remarks Removal tool 9570/1 See Workshop Equipment Manual, Chapter 2.2.2 Clips for removing radio

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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 removal. => Teaching the car radio The car radio has an optical waveguide (LWL). For information on the optical waveguide (LWL): 97, 9768 Optical waveguide (LWL) Switch ignition off and remove ignition key.

91 24 19 Removing and installing the car radio as of MY 2003

1733

einordnung

1. Insert removal tool into the openings provided on the radio until the tool is felt to engage. 2. Pull the radio completely out of the installation slot with the removal tool.

3. Carefully place the radio on the centre console in front. It is advisable to place a cloth between the centre console and the radio. 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, amplifier). The variant without additional audio components (external Most control units) has a jumper (output to input) connected to the optical waveguide plug.

5. Press in the (coloured) detent hooks on the radio arrow and withdraw the removal tool at the same time. top of page

Removing the car radio

1734

einordnung

Installing the car radio

1. Before the new radio is installed, unlock and disconnect the protective plug A for the optical waveguide.

2. Press in electrical plug and optical waveguide plug on car radio until the plugs are felt to engage a . Note Before sliding the car radio into the installation slot, make sure that the electrical leads are not trapped by the car radio or damaged. 3. Push the car radio into the installation slot 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 the codes from IPAS or from your importer by specifying the vehicle identification number. If possible, before the car radio is removed and replaced, a readout of the vehicle data should be obtained and noted down using the Porsche System Tester. During coding, the power supply for the Porsche System Tester should be guaranteed. Connect a battery charging device to the vehicle battery. Installing the car radio 1735

einordnung Symbol for the TAB key = | The Porsche System Tester instructions take precedence and in the event of a discrepancy these are the instructions that must be followed. A discrepancy may arise with later software versions (from 20.0). The procedure described here has been structured generally; different text or additions may appear in the Porsche System Tester. 1. Connect the Porsche System Tester to the vehicle and start the System Tester. Switch on ignition. Press >> to continue. 2. Select vehicle type using the cursor keys. 3. Using the >> key, move from the vehicle type to the list of control modules. 4. Select CDR23 with the cursor keys and press the >> key. 5. In the CDR23 menu, with the cursor keys on CDR23 press the >> key. 6. Select Coding with the cursor keys and press the >> key. 7. If possible, select 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 >> key. 10. Select CDR23 code in the Coding menu and press >> to continue. 11. Enter the IPAS CDR23 code and code it with the F8 key. 12. Follow the instructions on the Tester. Note In the case of a new car radio, continue with Step 13. 13. Select Traffic broadcast loudspeaker boost menu and code with the F8 key. 14. Select GAL (noisedependent loudspeaker boost) menu and code with the F8 key. 15. Select Vehicle version vehicle coding and code with the F8 key. Vehicle version vehicle coding Not coded Coup Cabrio Targa 16. Select Air conditioning and code with the F8 key. Air conditioning Without air conditioning With air conditioning 17. Select Right/lefthand drive vehicle coding and code with the F8 key. Right/lefthand drive vehicle coding Lefthand drive Teaching the car radio 1736

einordnung Righthand drive 18. Select Production mode and press >> . 19. Select Production mode Off and code with the F8 key. 20. Select Tuner parameters menu and code with the F8 key. Tuner parameters Europe USA South America Australia Asia (South) Africa Japan 21. Exit the Coding menu and switch to MOST actual installed components list in the CDR23 menu. Note The installed components that 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 components list . 22. In the menu CDR23 select MOST required installed components list . 23. If 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 CDR23 menu using the << key, read out the fault memory and erase it if necessary. 25. Exit the CDR23 menu using the << key. Note Switch on the car radio. If the car radio cannot be switched on, or the car radio switches on but no music can be heard, switch off the ignition, remove the ignition key, close the doors and lock the vehicle. Wait until the alarm system LED flashes normally . Unlock the vehicle and switch on the radio again. If the radio still does not switch on after this procedure, proceed in accordance with the Technical Manual. 0, 9101 PCM/CDR23

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Teaching the car radio

1737

91 42 19 Removing and installing rear loudspeakers, Bose sound package

Removing rear loudspeakers Installing rear loudspeakers

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Removing rear loudspeakers

91 42 19 Removing and installing rear loudspeakers, Bose sound package

1738

einordnung

No. 1 2 3 4

Procedure Removing cover trim Undoing fastening screw Pulling out the sound package Disconnecting the plug connection.

Instructions Remove the cover trim 1 at the left and right towards the front. Unscrew the fastening screw 2 at the left and right. Pull the sound package 3 in the direction of the arrow out of the bracket 4 and fold over. Press plugs 5 together and pull apart.

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Installing rear loudspeakers

Removing rear loudspeakers

1739

einordnung

No. 1 2 3 4

Procedure Connecting plug connection Positioning sound package Fastening the sound package Attaching the cover trim

Instructions Push in the plug connection 5 until the plug engages. Push the sound package 3 into the bracket 4 as far as the stop. Screw in the fastening screws 2 at the left and right. Tightening torque: 7.2 Nm (5.5 ftlb.) Position the cover trim 1 and press into place.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing rear loudspeakers

1740

91 44 19 Removing and installing the loudspeaker amplifier

Removing the loudspeaker amplifier Installing the loudspeaker amplifier

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Removing the loudspeaker amplifier

Before removing the amplifier, take out the ignition key and switch off the audio system.

91 44 19 Removing and installing the loudspeaker amplifier

1741

einordnung

1. Open the luggagecompartment lid and if present, detach the additional amplifier on the clip 1 and detach the additional amplifier (in the direction 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 electrical connectors arrow .

Harman amplifier: 5. Remove the cover for the electrical connector.

Removing the loudspeaker amplifier

1742

einordnung

Harman amplifier: 6. Unplug both electrical connectors arrow .

7. Unscrew both fastening screws and pull 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 until they perceptibly engage.

Bose amplifier:

Installing the loudspeaker amplifier

1743

einordnung

Harman amplifier:

3. Put on the cover on the Harman amplifier.

4. Screw on the retaining bracket with the amplifier 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, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing the loudspeaker amplifier

1744

91 74 19 Removing and installing control module for parking assistant

Note Removing control module for parking assistant Installing control module for parking assistant Note The control module for the parling assistant is located under the left front seat. Before removing the control module, remove the ignition key. Removing front seat 720119 Removing and installing front seat.

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Removing control module for parking assistant

1. Unscrew both fastening screws arrow from the cover.

2. Turn the cover over and disconnect both electrical plugs. 3. Unscrew the control module from the cover with the two fastening screws.

91 74 19 Removing and installing control module for parking assistant

1745

einordnung top of page

Installing control module for parking assistant

1. Insert both plugs into the 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, 996620, 996621, 996650, 996651

Removing control module for parking assistant

1746

91 84 19 Removing and installing antenna amplifier as of MY 2003

Removing antenna amplifier Installing antenna amplifier

Note The antenna amplifier is installed in connection with the PCM2. The antenna amplifiers are located on the Apillars.

top of page 91 84 19 Removing and installing antenna amplifier as of MY 2003 1747

einordnung

Removing antenna amplifier

Remove the respective trim of the Apillar 7, 705719 Removing and installing Apillar trim

1. Disconnect the antenna plugs for the windscreen 1 and 2 . 2. Disconnect the plug connections for the antenna control module 3, 4 left side, 3, 4, 5 right side. 3. Unscrew the two fastening screws 6 . top of page

Installing antenna amplifier

1. Position the antenna amplifier on the Apillar and screw the fastening screws 6 tight. 2. Connect the plug connections for the antenna control module 3, 4 left side, 3, 4, 5 right side. 3. Connect the antenna plugs for the windscreen 1 and 2 . Install the respective trim of the Apillar 7, 705719 Removing and installing Apillar trim

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Removing antenna amplifier

1748

91 86 19 Removing and installing control module for antenna

Removing control module for antenna Installing control module for antenna

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Removing control module for antenna

Remove the right cover under the instrument panel 7, 702219 Removing and installing cover under instrument panel . Remove the ignition key and switch off the radio.

91 86 19 Removing and installing control module for antenna

1749

einordnung

1. Lever the control module on the left side out of the clip and pull it to the right out of the holder.

2. Swivel the control module 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

Installing control module for antenna

1. Connect the electrical plugs successively.

Removing control module for antenna

1750

einordnung

2. Carefully push the control module over the passenger compartment carpet B and position the module 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, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing control module for antenna

1751

91 90 19 Removing and installing control module for telephone

Removing control module for telephone Installing control module for telephone Remove right front seat. 7, 720119 Removing and installing front seat Switch off ignition, remove key, switch off PCM or radio.

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Removing control module for telephone

1. Unscrew the 4 fastening screws from the holder.

2. Unscrew the 2 fastening screws from the holder and remove the control module from the holder.

3. Disconnect the electrical plug connections. top of page

91 90 19 Removing and installing control module for telephone

1752

einordnung

Installing control module for telephone

1. Connect the electrical plug connections on the control module.

2. Position the control module on the holder 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 Removing and installing front seat

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Installing control module for telephone

1753

92 12 19 Removing and installing rain sensor

Removing rain sensor Installing rain sensor Open circuit in the rain sensor connection (emergency interval operation)

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Removing rain sensor

92 12 19 Removing and installing rain sensor

1754

einordnung

Limited functionality of the rain sensor when the following information points are not observed: Note An adhesive pad must be used when reinstalling the rain sensor. See PET, main group 9, sub group 04. When assemblying the adhesive pad, air should not be trapped between the windscreen and the adhesive pad or between the adhesive pad and the rain sensor. When installing the adhesive pad, a temperature of approx 20C for the windscreen, the rain sensor and the adhesive pad must be ensured. Carefully heat the windscreen with a hotair gun for example. The sensor on the sticking surface must not be touched by fingers. If the sensor is new, remove the protection cap before the sensor is stuck onto the windscreen.

Removing rain sensor

1755

einordnung When sticking a new sensor, make sure that no air pockets are caught between the gel and the windscreen. Air pockets could impair the function of the sensor. Sensor, orientation lights, wires and wiring ducts are spare parts. If the old rain sensor is installed: begin with the instructions on Page 5. No. Procedure 1 Removing cover of infrared interior sensor 2 Line routing 3 Instructions Remove both covers and unscrew both screws 1 .

Disengage holder 2 for the line arrow and pull line forward behind the headliner. Disconnecting the plug connection Press plugs 3 and pull apart arrow .

No. Procedure Removing rain sensor

Instructions 1756

einordnung 1 2 3 4 5 6 7 Removing cover of rain sensor Removing orientation lights Disconnecting the plug connection Removing mirror Unclipping rain sensor holder Undoing rain sensor from the windscreen Pull of adhesive pad Unclip the cover 1 of the rain sensor from above. Remove orientation lights 2 . Carefully pull out the plug connection 3 out of and apart from the holder. Fold mirror 4 downwards and push down from the bracket. Carefully unclip holder 5 of rain sensor at the top, bottom left and right. Remove rain sensor 6 slowly from the windscreen. If the rain sensor is reinstalled, then slowly pull the adhesive pad 7 off the rain sensor.

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Installing rain sensor

Installing rain sensor

1757

einordnung

Note Observe notes: => Removing rain sensor If the removed rain sensor is reinstalled, the surfaces must be free of adhesive residues. Do not use harsh cleaning agents. Stick the adhesive pad onto the rain sensor at a temperature of approx. 20C.

No. 1 2 3 4 5

Procedure Sticking on rain sensor Clip in holder Push on rearview mirror Pushing on plug Inserting orientation lights

Instructions Push the rain sensor 6 onto the windscreen. Push and press holder 5 onto the rain sensor until it engages. Push rearview mirror 4 onto the mirror holder from below. Join the plug connection 3 and insert into the mirror base. Inserting orientation lights 2 into the cover. 1758

Installing rain sensor

einordnung 6 Attaching cover of mirror base Join both covers 1 , ensuring that the orientation light is correctly positioned.

No. Procedure 1 Connecting the plug connection 2 Line routing 3 Mounting cover of infrared interior sensor

Instructions Press the plug connection 3 together. Engage holder 2 for the line and push in line behind the headliner. Tighten fastening screws 1 and clip in both infrared interior sensor covers.

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Installing rain sensor

1759

einordnung

Open circuit in the rain sensor connection (emergency interval operation)

Note The rain sensor control module independently detects a faulty rain sensor. Fixed intervals are allocated 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 be checked and replaced if necessary.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Open circuit in the rain sensor connection (emergency interval operation)

1760

92 13 19 Removing and installing control module for rain sensor

Note Removing control module 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 trim.

top of page 92 13 19 Removing and installing control module for rain sensor 1761

einordnung

Removing control module for rain sensor

WARNING When working in the area of the wiper link, the ignition key must be removed. No. Procedure Instructions Remove the cover above the battery and fluid tank. Turn on the windscreen wiper system and when the wiper reaches a vertical position on the windscreen turn off the ignition. 1 Removal of cover for rain sensor Unscrew fastening screws for cover. control module Switch on ignition and let wiper link run in end position. 2 Removing plug of rain sensor Remove cover with control module. control module Open slide control of plug A and remove plug B .

Removing control module for rain sensor

1762

einordnung 3 Disconnect control module from the Pull the control module out of the cover on the side of the cover electrical plug connection.

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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 Push the control module into the cover, ensuring a secure fit. module with the cover 2 Installing control module for rain sensor 1763

einordnung Postioning seal of cover Connecting battery Mount cover with control module. Place the seal onto the cover and position correctly. If the seal is damaged, replace for safety reasons. Plug in electrical plug connection B and lock plug A . Put on cover with control module. Switch ignition on and actuate windscreen wiper, windscreen wipers are vertical, switch off ignition. Tighten fastening screws. Ignition on, windscreen wiper runs in end position, ignition off. Tightening fastening screw. Install cover for battery and fluid container on the left (cowl panel).

3 4

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Safety function in the 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 activated. If the windscreen wiper does not move despite the appropriate power supply, actuation of the windscreen wiper motor is interrupted after 3 seconds. 2. The front windscreen wiper locks after leaving the parking position. In both cases all operating modes are blocked after a motor block. The system can only be reactivated after the steering column switch has returned to the >OFF< position. If one of these faults is present, replace the rain sensor control module.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651

Safety function in the event of failure (engine blockage)

1764

96 64 32 Converting installation position for tilt sensor, additional alarm system M536
Note Tools Note As from model year 2002, the tilt sensor will be installed under the left front seat next to the alarm control module. In vehicles up to model year 2001 inclusive, the tilt sensor is located in the radiator tank to the right of the battery. If a new tilt sensor must be replaced in vehicles produced before model year 2002, the conversion prcedure described below must be carried out. In connection 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. Disconnect battery 9 Work instructions after disconnecting the battery. Use the wiring diagram for the central locking alarm system, sheet 8 / 8A.

1. Remove the battery cover and the right cowl panel cover. 2. Pull off the plug on the tilt sensor. 3. Unscrew the fastening nut arrow . 4. Remove the tilt sensor and tie the electrical lead with insulating tape. 5. Fit the battery cover and the right cowl panel cover.

96 64 32 Converting installation position for tilt sensor, additional alarm system M536

1765

einordnung

6. Remove the left front seat 720119 Removing and installing front seat, Group 7, Chapter 721 . 7. If a control module with parking assistant is installed, remove the bracket. To do so, unscrew the two fastening screws arrow and disconnect both plugs. => Removing and installing control module for parking assistant 8. Remove the alarm system control module. => Removing and installing control unit 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 pressout tool 90207, insulate the lead and tie it to the wiring harness. => Tools 11. Push the pin of the grey lead from the service set into the plug for pin 38 until it engages and push the pin of the grey/black lead into the plug for pin 11 until it, too, engages. => Tools 12. Push the pin strip B into the plug sleeve A and lock the plug.

96 64 32 Converting installation position for tilt sensor, additional alarm system M536

1766

einordnung

13. Lay the red/brown lead C from the service wiring harness to the plug (black) of the alarm system control module, crimp the lead to the red/brown lead, pin B8 wiring diagram, external loads, terminal 30 and insulate the lead. The leads must be watertight. => Tools 14. Insert the plug for the alarm control module and fit the control module to the floorpan. 15. Engage the tilt sensor on the tilt sensor bracket. 16. Insert the service lead plug into the tilt sensor.

17. Fit the parking assistant control module to the new cover 1 with the fastening screws 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 screws arrow . 19. Lay the lead under the cover, making sure that no electrical lead can be caught when the seat is operated. 20. Install the seat 720119 Removing and installing front seat. 21. Make sure the system is functioning properly with the Porsche System Tester. top of page

Tools

Item 1 2

Designation of the special tool Repair set for wiring harness 1551 Pressout tool 155

Remarks Workshop Equipment Manual, Gr. 2.4 Workshop Equipment Manual, Gr. 2.4

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Tools

1767

96 87 19 Removing and installing control unit for alarm 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 Removing and installing control unit for alarm system

1768

einordnung

Note Only remove the control unit with the battery disconnected => Work instructions after disconnecting the battery Code numbers from IPAS 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 vehicle; a transfer to a different vehicle is not possible.

No. Procedure

Instructions 1769

Removing control unit for alarm system

einordnung Remove the left front seat 720119 Removing and installing front seat, 72 1. Opening lock Open the lock 1 by turning in the direction of the arrow . Take the control unit out of the bracket and turn it around. Disconnecting the Press connectors 2 together and pull apart. connectors Disconnecting the Press the locking arrow , fold back the lever and pull off the connector connectors 3 . Pull off the connector 4 .

1 2 3

top of page

Installing control unit for alarm system

Note Installing control unit for alarm system 1770

einordnung Only install the control unit with the battery disconnected => Work instructions after disconnecting the battery

No. 1 2 3

Procedure Instructions Inserting the connectors Insert the connector 2 until it engages. Inserting the connectors Insert connector 4 . Insert connector 3 and move the clip until it engages. Screwing control unit Engage the control unit in the opening on the vehicle floor and close tight the lock 1 in the direction of the arrow . Installing left front seat 720119 Removing and installing front seat, 72 1.

top of page

Teaching control unit for the alarm system

Note 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 vehicle; a transfer to a different vehicle is not possible. As soon as the immobilizer code has been entered and confirmed, it can 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 Tester have highest priority. Code numbers from IPAS are required. 1. Switch on the ignition, connect the Porsche System Tester to the vehicle and start the System Tester. 2. Select the menu Vehicle type , Alarm system , then Learning functions . 3. Select the menu Read out remote controls , enter the key learning code and confirm with F7. 4. The Tester confirms that the remote controls have been read. 5. Ignition off, disconnect the battery and remove the control unit. 6. Install the new control unit, connect the battery, switch on the ignition, Alarm system menu, >> , Learning functions menu. 7. Select the menu Immobilizer , enter the immobilizer code and confirm with F7. 8. Select the menu Transfer remote controls , enter the key learning code and confirm with F7. 9. Select the menu Transponder key , enter the key learning code and confirm with F7. Note

Teaching control unit for the alarm system

1771

einordnung As the transponder coils must be taught individually, make sure that the allocation of the position is taught as shown in the IPAS printout. 10. The Porsche System Tester shows four positions. Under Current key , the transponder code of the inserted key is shown. Check this code is in the same position as on the IPAS printout and confirm with F8. 11. Withdraw the key and repeat steps 9 to 10 for the remaining keys. 12. In the 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 coding , the locking of the doors can be adjusted 9601 Control unit function, Group 0 Diagnosis . 14. In vehicles with the Mnumber 536, an alarm siren/tilt sensor is also installed, which must be activated in the menu Alarm siren/tilt sensor . 15. The teaching process has been completed; start the engine.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Teaching control unit for the alarm system

1772

97 89 19 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 distributor

1773

einordnung

No. Procedure Disconnecting battery

1 2 3

Instructions Remove the battery cover and the cover of the right radiator tank 702219 Removing and installing cowl panel cover. 9 Work instructions after disconnecting the battery. Disconnect and cover the ground terminal on the battery. Current distributor Pull off the covering cap 1 . Unscrew the B+ connection 2 . Unscrew fastening fastening nuts 3 . Cover in passenger's Unscrew both plastic screws 4 and remove the cover 5 downwards. footwell Lowering the Disconnect the tiewrap 7 from the water drainage 6 and pull off the current distributor water drainage 6 . Press the current distributor A away from the firewall arrow and lower downwards into the passenger's footwell. Opening the current Disengage the lock arrow in the direction of the arrow and fold the cover distributor open. Remove the service label 8 original green , aftersales service red or blue . 1774

Removing current distributor

einordnung 5 Disconnecting the connection lines Mark the connection lines C to the relevant fusible element. Disconnect connection lines C and positive lead B+ B . Disconnect tiewrap 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 label, red Depending on condition, flange seal current distributor/firewall Tiewraps

Installing the current distributor

1775

einordnung

No. Procedure Instructions 1 Connecting the Connect the connection lines C and the positive lead B+ B to the current connection lines distributor in the correct order. Fasten the lines to the current distributor with the tiewrap 9 . Use the marking, the wiring diagram and new nuts. M 6 tightening torque: 8 Nm (6 ftlb.) M 8 tightening torque: 15 Nm (11 ftlb.) 2 Closing and Close the cover until both locking elements arrow engage. Affix the service sealing the label 8 red . current distributor 3 Installing the Check the flange seal between the current distributor and the firewall for current damage and replace, if necessary. Push the current distributor A into place distributor between the heating/airconditioning unit and the firewall. Move the current distributor in the direction of the arrow until the studs of the current distributor A fit into the firewall.

Installing the current distributor

1776

einordnung Connect the water drainage 6 and fasten with a tiewrap 7 . Tighten both hexagon nuts 3 . Connect the B+ lead 2 and screw into place with a new M 8 hexagon nut. M 8 tightening torque: 15 Nm (11 ftlb.) Press cover cap 1 on. Position the cover 5 from below and screw tight with the two fastening screws 4 .

Screwing the current distributor tight

Cover in passenger's footwell Connecting the 9 Work instructions after disconnecting the battery. battery Installing the 702219 Removing and installing cowl panel cover. cowl panel cover

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installing the current distributor

1777

97 92 19 Removing and installing fusible element in the current distributor

Removing fusible element from the current distributor Installing fusible element in the current distributor top of page

Removing fusible 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 arrow . This will break the locking tabs and the cover can be removed.

3. Remove the broken locking tabs from the current distributor.

97 92 19 Removing and installing fusible element in the current distributor

1778

einordnung 4. Unscrew the two hexagon nuts M 5 3 from the blown fusible element 1 and remove with the washers 2 . top of page

Installing fusible element in the current distributor

Note The following spare parts must be replaced. Hexagon nut M 8, 1 piece Repair kit replacement 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 aftersales service cover A . 3. Close the current distributor cover until it engages arrow . 4. Affix the blue service label. 5. => Installing the current distributor

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Removing fusible element from the current distributor

1779

911 Turbo (996) Technical Manual

General Structure Breakdown of Repair Groups Legend for structure of sequence description Structure of exploded view Structure of sequence description top of page

General
The Technical Manual Repair describes all essential work operations requiring special instructions to ensure that repairs are performed properly. It should be in the hands of the workshop foremen and the workshop personnel, as careful compliance with the stated instructions is a precondition for maintaining the traffic and operating safety of the vehicle. In addition, 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 / general Description of repairs

top of page

Breakdown of Repair Groups

Tools, special tools and materials required for repair Exploded drawings and illustration of sequence Legend for exploded drawing and description of sequence Instructions for assembly and adjustment The Technical Manual is regularly expanded by supplements, which must be incorporated immediately to preserve the usefulness of the Manual. As verification of completeness, the record sheet should be completed. top of page

Legend for structure of sequence description

911 Turbo (996) Technical Manual

1780

einordnung

A B C D E F G H I J N

Repair Group, number Repair Group, number Repair group, text Vehicle type Page number Internal Porsche number Work operation, consisting of ''Aftersales service number'' and ''Title'' Imprint, year of printing Title of legend for structure Structure of legend Structure of legend

top of page

Legend for structure of sequence description

1781

einordnung

Structure of exploded view

A B C D E F G H I J K

Repair Group, number Repair Group, number Repair group, text Vehicle type Page number Internal Porsche number Work operation, consisting of ''Aftersales service number'' and ''Title'' Imprint, year of printing Title of exploded drawing No. of exploded drawing, in order of disassembly No. of exploded drawing, in order of disassembly 1782

Structure of exploded view

einordnung M Description or explanation of procedure top of page

Structure of sequence description

A B C D E

Repair Group, number Repair Group, number Repair group, text Vehicle type Page number 1783

Structure of sequence description

einordnung F G H I J K L M Internal Porsche number Work operation, consisting of ''Aftersales service number'' and ''Title'' Imprint, year of printing Title of structure sequence description Sequence number, in order of sequence Sequence number, in order of sequence Procedure in the sequence Description or explanation of procedure

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Structure of sequence description

1784

97 Wiring diagram for 911 Turbo (996), 01 model

Sheet 1 Sheet 1A Sheet 2 Sheet 2A Sheet 3 Sheet 3A Sheet 3B Sheet 4A Sheet 5 Sheet 5A Sheet 6 Sheet 7 Sheet 8 Sheet 8A Sheet 9 Sheet 9A Sheet 10 Sheet 10A Sheet 11 Sheet 11A Sheet 11B Sheet 12 Sheet 12A Sheet 13 Sheet 13A Sheet 14 Sheet 15 Sheet 15A Sheet 16 Sheet 16A Sheet 17 Sheet 17A Sheet 26 Sheet 27 Contents Lights RoW Lights USA / Canada Instrument cluster / sensor Spoiler Wiper and washer system, headlight cleaning system, rear window wiper Wiper and washer system, headlight cleaning system, rain sensor Twotone horns Climatronic Mirror adjustment, heated rear window Memory Sliding roof Power windows Central locking, alarm system (LHD) Central locking, alarm system (RHD) Airbag, POSIP (LHD) Airbag, POSIP (RHD) ABS GT2 PSM Tiptronic Seat Transmission cooling GT2 DME vehicle area DME engine area Radio for standard GT2 Radio, sound package Parking assistant Info/ navigation system PCM Telephone, telephone preparation Power supply Power supply GT2 Ground points (LHD) Ground points (RHD) Relay carrier, assignment, jumper plugs Fuse assignments

The wiring diagram consists of individual wiring diagrams and overview sheets for ground points, components, plug connections, connection points, relay carriers 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. 97 Wiring diagram for 911 Turbo (996), 01 model 1785

einordnung The plug connections are identified with X and a number. 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

97 Wiring diagram for 911 Turbo (996), 01 model

1786

97 Wiring diagram for 911 Turbo (996), 02 model

Sheet 1 Sheet 1A Sheet 2 Sheet 2A Sheet 3 Sheet 3A Sheet 3B Sheet 4 Sheet 4A Sheet 5 Sheet 5A Sheet 5B Sheet 5C Sheet 5D Sheet 6 Sheet 7 Sheet 8 Sheet 8A Sheet 9 Sheet 9A Sheet 10 Sheet 10A Sheet 11 Sheet 11A Sheet 12 Sheet 12A Sheet 13 Sheet 13A Sheet 13B Sheet 14 Sheet 15 Sheet 15A Sheet 16 Sheet 16A Sheet 17 Sheet 17A Sheet 20 Sheet 21 Contents Lights RoW Lights USA / Canada Instrument cluster / sensor Spoiler Wiper and washer system, headlight cleaning system, rear window wiper Wiper and washer system, headlight cleaning system, rain sensor Twotone horns, cigarette lighter Heating Climatronic Mirror adjustment (LHD) Memory (LHD) Mirror adjustment (RHD) Memory (RHD) Seat Sliding roof Power windows Central locking, alarm system (LHD) Central locking, alarm system (RHD) Airbag, POSIP (LHD) Airbag, POSIP (RHD) ABS GT2 PSM Tiptronic Transmission cooling DME vehicle area DME engine area Radio for standard GT2, radio preparation Harman sound package analog Bose sound package analog Parking assistant Info/ navigation system PCM Telephone, mobile phone analog Power supply Power supply GT2 Ground points (LHD) Ground points (RHD) Fuse assignments Relay carrier, assignment, jumper plugs

97 Wiring diagram for 911 Turbo (996), 02 model

1787

einordnung Sheet 22 Sheet 23 Sheet 24 Sheet 25 Sheet 28 Components Plug connections, abbreviations Connection points / plug Overview of plugs Vehicle overview

The wiring diagram consists of individual wiring diagrams and overview sheets for ground points, components, plug connections, connection points, relay carriers 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 are identified with X and a number. 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, 996840, 996841

97 Wiring diagram for 911 Turbo (996), 02 model

1788

97 Circuit diagram for 911 Turbo (996), '03 model

Sheet 1 Sheet 1A Sheet 2 Sheet 2A Sheet 3 Sheet 3A Sheet 3B Sheet 4A Sheet 5 Sheet 5A Sheet 5B Sheet 5C Sheet 5D Sheet 6 Sheet 7 Sheet 8 Sheet 8A Sheet 9 Sheet 9A Sheet 10 Sheet 10A Sheet 11 Sheet 11A Sheet 12 Sheet 12A Sheet 13 Sheet 13A Sheet 13B Sheet 13C Sheet 14 Sheet 15 Sheet 15A Sheet 15B Sheet 16 Sheet 16A Sheet 17 Sheet 17A Sheet 20 Contents Lights RoW Lights USA/Canada Instrument cluster/sensor Spoiler Wiper and washer system, headlight cleaning system, rear window wiper Wiper and washer system, headlight cleaning system, rain sensor Twotone horns, cigarette lighter Climatronic Mirror adjustment (LHD) Memory (LHD) Mirror adjustment (RHD) Memory (RHD) Seat Sliding roof Power windows Central locking, alarm system (LHD) Central locking, alarm system (RHD) Airbag, POSIP (LHD) Airbag, POSIP (RHD) ABS GT2 PSM Tiptronic Transmission cooling GT2 DME vehicle area DME engine area Radio for standard GT2 Harman sound package digital Bose sound package digital CD changer ParkAssist Info/navigation system PCM2 Telephone, mobile phone Telephone Power supply Power supply GT2 Ground points (LHD) Ground points (RHD) Fuse assignments

97 Circuit diagram for 911 Turbo (996), '03 model

1789

einordnung Sheet 21 Sheet 22 Sheet 23 Sheet 24 Sheet 25 Sheet 26 Sheet 26 Sheet 27 Sheet 27 Sheet 30 Relay carrier, assignment, jumper plugs Components Plug connections, abbreviations Connection points/plug Overview of plugs Optical wave guide, lefthand drive, sheet 1 of 2 Optical wave guide, righthand drive, sheet 2 of 2 Antenna leads, lefthand drive, sheet 1 of 2 Antenna leads, righthand drive, sheet 2 of 2 Vehicle 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 diagrams are subdivided into coordinate fields. The ground points are identified by GP and their locations are shown in a vehicle diagram. The plug connections are identified with X and a number. 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, 996840, 996841

97 Circuit diagram for 911 Turbo (996), '03 model

1790

97 Circuit diagram for 911 Turbo (996), '04 model

Sheet 1 Sheet 1A Sheet 2 Sheet 2A Sheet 3 Sheet 3A Sheet 3B Sheet 4A Sheet 5 Sheet 5A Sheet 5B Sheet 5C Sheet 5D Sheet 6 Sheet 6A Sheet 7 Sheet 7A Sheet 8 Sheet 8A Sheet 9 Sheet 9A Sheet 10 Sheet 10A Sheet 11 Sheet 11A Sheet 12 Sheet 12A Sheet 13 Sheet 13B Sheet 13C Sheet 14 Sheet 15 Sheet 15A Sheet 15B Sheet 16 Sheet 16A Sheet 17 Sheet 17A Contents Lights RoW Lights USA/Canada Instrument cluster/sensor Spoiler Wiper and washer system, headlight cleaning system, rear window wiper Wiper and washer system, rain sensor Twotone horns, cigarette lighter Climatronic Mirror adjustment (LHD) Memory (LHD) Mirror adjustment (RHD) Memory (RHD) Seat Sliding roof Cabriolet poweroperated convertible top Power windows Power windows, Cabrio Central locking, alarm system (LHD) Central locking, alarm system (RHD) Airbag, POSIP (LHD) Airbag, POSIP (RHD) ABS 5.7 GT2 PSM Tiptronic Transmission cooling GT2 DME vehicle area DME engine area Radio for standard GT2 Bose sound package digital CD changer ParkAssist Info/navigation system PCM2 Telephone, mobile phone Telephone Power supply Power supply GT2 Ground points (LHD) Ground points (RHD)

97 Circuit diagram for 911 Turbo (996), '04 model

1791

einordnung Sheet 20 Sheet 21 Sheet 22 Sheet 23 Sheet 24 Sheet 25 Sheet 26 Sheet 26 Sheet 27 Sheet 27 Sheet 30 Fuse assignments Relay carrier, assignment, jumper plugs Components Plug connections, abbreviations Connection points/plug Overview of plugs Optical wave guide, lefthand drive, sheet 1 of 2 Optical wave guide, righthand drive, sheet 2 of 2 Antenna leads, lefthand drive, sheet 1 of 2 Antenna leads, righthand drive, sheet 2 of 2 Vehicle 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 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 are identified with X and a number. 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, 996840, 996841, 996620, 996621, 996650, 996651

97 Circuit diagram for 911 Turbo (996), '04 model

1792

97 Circuit diagram for 911 Turbo (996), '05 model

Sheet 1 Sheet 1A Sheet 2 Sheet 2A Sheet 3 Sheet 3A Sheet 3B Sheet 4A Sheet 5 Sheet 5A Sheet 5B Sheet 5C Sheet 5D Sheet 6 Sheet 6A Sheet 7 Sheet 7A Sheet 8 Sheet 8A Sheet 9 Sheet 9A Sheet 10 Sheet 10A Sheet 11 Sheet 11A Sheet 12 Sheet 12A Sheet 13 Sheet 13B Sheet 13C Sheet 14 Sheet 15 Sheet 15A Sheet 15B Sheet 16 Sheet 16A Sheet 17 Sheet 17A Contents Lights RoW Lights USA/Canada Instrument cluster/sensor Spoiler Wiper and washer system, headlight cleaning system, rear window wiper Wiper and washer system, rain sensor Twotone horns, cigarette lighter Climatronic Mirror adjustment (LHD) Memory (LHD) Mirror adjustment (RHD) Memory (RHD) Seat Sliding roof Cabriolet poweroperated convertible top Power windows Power windows, Cabrio Central locking, alarm system (LHD) Central locking, alarm system (RHD) Airbag, POSIP (LHD) Airbag, POSIP (RHD) ABS 5.7 GT2 PSM Tiptronic Transmission cooling GT2 DME vehicle area DME engine area Radio for standard GT2 Bose sound package digital CD changer ParkAssist Info/navigation system PCM2 Telephone, mobile phone Telephone Power supply Power supply GT2 Ground points (LHD) Ground points (RHD)

97 Circuit diagram for 911 Turbo (996), '05 model

1793

einordnung Sheet 20 Sheet 21 Sheet 22 Sheet 23 Sheet 24 Sheet 25 Sheet 26 Sheet 26 Sheet 27 Sheet 27 Sheet 30 Fuse assignments Relay carrier, assignment, jumper plugs Components Plug connections, abbreviations Connection points/plugs Overview of plugs Optical wave guide, lefthand drive, sheet 1 of 2 Optical wave guide, righthand drive, sheet 2 of 2 Antenna leads, lefthand drive, sheet 1 of 2 Antenna leads, righthand drive, sheet 2 of 2 Vehicle 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 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 are identified with X and a number. In the case of lines that branch off onto another sheet, the coordinates and, in some cases, the terminal designations are specified.

996420, 996421, 996840, 996841, 996620, 996621

97 Circuit diagram for 911 Turbo (996), '05 model

1794

Preconditions for using workshop documentation for Porsche vehicles

This data comprises technical information as well as instructions on repairs for Porsche vehicles and documentation for training purposes. The descriptions are intended for the exclusive use by workshops and their workshop staff. Note The Dr. Ing. h.c. F. Porsche AG retains sole ownership of the copyright. It may not be transmitted to third parties. Graphics and text may not be duplicated or used in other electronic or printed publications without the express consent of the Dr. Ing. h.c. F. Porsche AG. General preconditions for repairing Porsche vehicles The descriptions form the basis for professional and correct maintenance and repair work. The content of the work procedures described is based on the level of training of a fitter with a sound knowledge of the product. The fitter must have obtained knowledge of the product at training programs and courses offered by the Dr. Ing. h.c.F. Porsche AG which are specific to the product and assembly before carrying out any of the work. This level of knowledge is the precondition for carrying out the work described. The Dr. Ing. h.c. F. Porsche AG will not be held liable if the described repair work is carried out without this knowledge. Preconditions for body work on Porsche vehicles The described repair work only applies to standard cases. Body repairs must only be carried out by skilled persons who are specialised for such work. Given the overall picture of the damages, the workshop itself must decide whether it is possible to return the vehicle to its proper 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 correctly and according to the Dr. Ing. h.c. F. Porsche AG instructions for sheetmetal, paint and corrosion protection/preservation work. Warning notes and safety instructions The warning notes and safety instructions are classified by the respective signalising word (Danger, Warning, Caution) beside the warning symbol. DANGER Warns against death or very serious injury which will certainly occur if the instructions are not observed. WARNING Warns against death or very serious injury which may occur if the instructions are not observed. CAUTION Warns against minor injury or damage to property if the instructions are not observed. To prevent injury and restricted operating and traffic safety of the vehicle, or damage to the vehicle as the result of incorrect work, read these warning notes and safety instructions carefully and observe them without fail. It is not possible for Dr. Ing. h.c. F. Porsche AG to give a detailed evaluation of all danger situations for the persons carrying out the work. It is therefore imperative that all persons carrying out repair and maintenance work on Porsche vehicles use their specialist knowledge to ensure that their own safety is not at risk and the procedure chosen will not have any negative effects on the vehicle especially with regard to safety. It is therefore expressly specified that all work involved in the work procedures described should be carried out only in accordance with the valid guidelines and regulations of the local authorities responsible with Preconditions for using workshop documentation for Porsche vehicles 1795

einordnung respect to health and accident prevention and environmental protection, and in compliance with the applicable legal requirements and regulations. Notes Notes contain advisory information related to the work procedure which makes the fitter's work easier. The following pictogram indicates this information: Note Contains advisory information which makes 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. Any existing deviations are corrected by means of supplements, and the scope of the descriptions is extended with supplements. The Dr. Ing. h.c. F. Porsche AG retains the right to implement changes at any time and without prior notice.

9paad1, 9paad7, 9paae1, 9paae7, 9paaf1

Preconditions for using workshop documentation for Porsche vehicles

1796

01 Mobile roofs: checking function

Checking sliding roof Checking convertible top Checking the hardtop top of page

Checking sliding roof

1. Check sliding roof when opening and closing for function and noises. top of page

Checking convertible top

1. Remove hardtop if present. 2. This is done by pressing on the key with remote control (symbol button). Hold it in the unlocking position until the convertible top has reached its final position or until the door windows are in the desired position. Note Check that it is seated securely, which involves manually moving component against component. 3. Check the left and right front locating pegs on convertible top to ensure that they are secure and functioning properly. 4. Check the convertibletop peg housing on cowl panel frame to ensure that it is secure and functioning properly. top of page

Checking the hardtop

Note Check that it is seated securely, which involves manually moving component against component. 1. Remove hardtop if present. 2. Check the left and right front locating pegs on hardtop to ensure that they are secure and functioning properly. 3. Check the front hardtop lock to ensure that it is secure and functioning properly. 4. Check the rear hardtop lock on the left and right to ensure that it is secure and functioning properly. 5. Check the convertibletop peg housing on cowl panel frame to ensure that it is secure and functioning properly.

01 Mobile roofs: checking function

1797

einordnung 996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631

Checking the hardtop

1798

01 Glazing: visual inspection for damage

1. Visual inspection for film residue when removing the transport 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, 996431, 996620, 996621, 996650, 996651, 996630, 996631, 996840, 996841

01 Glazing: visual inspection for damage

1799

01 Checking lid and doors

Checking lid lock, front and rear Checking safety hook, front lid Function test, checking door lock Functional inspection of the tank cap lock top of page

Checking lid lock, front and rear

Check that the lid locks engage by insertion of the lock upper parts when the lids (front and rear) are closed and that they disengage again when the lid releases are pulled. top of page

Checking safety hook, front lid

1. Check that the front lid is held down by the 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

Function test, checking door lock

Check that the door lock engages in two stages through the locking wedge when the doors are closed and that it disengages again when the door handle is operated (inside and outside). top of page

Functional inspection of the tank cap lock

Lock vehicle. Check that the tank cap lock locks the tank cap in the closed position.

996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631, 996840, 996841

01 Checking lid and doors

1800

01 Interior equipment: visual inspection for damage and soiling

1. Visual inspection for film residue when 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, 996651, 996630, 996631, 996840, 996841

01 Interior equipment: visual inspection for damage and soiling

1801

01 Removing transport protection

1 Removing external transport protection 1 Removing internal transport protection top of page

1 Removing external transport protection

Installation Material 996 996 996 996 location Turbo GT2 C4S Turbo Cabriolet Front lid PP film, X XX X X white Rear lid PP film, X white Roof / PP film, X X X X Hardtop white Targa roof excluding frame protection Left and PP film, X X X X right wing. white Side panel PP film, X X X X left and white right. PP film, X X X X Side white member Aerokit on the driver's side Left and PP film, X X X X right doors. white Doors, PE profile X X X X left/right strip Styrodur strip Front Styropor X X X X bumpers block Rims 1) PVC EVA X X X X film Convertible non X Top woven + PEVA Softtop X cover
2)

01 Removing transport protection

1802

einordnung
1) Rim 2) Only

protection cover only in USA, Canada, Japan, Great Britain overseas

top of page

1 Removing internal transport protection

Installation location Material 996 Turbo, C4S, GT2, Turbo Cabriolet X X X X X X X X X

Seats (front)

PE film covering Inner sill IKS adhesive tape, blue Inner side Polypropylene member film Door trim panel TESA at bottom transparent (loudspeaker) film, red Footwell Cardboard insert Steering wheel Film covering Parking brake Cardboard protection PCM Film on the display Instrument cluster Cover

996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631, 996840, 996841

1 Removing external transport protection

1803

01 Installing air guides for PCCB brake discs GT2

Note Installing front air guides Installing rear air guides Note The air guides (brakeair spoiler) on the front suspension of GT2 vehicles with PCCB brakes are larger than those of a conventional brake system! Exclusively for PCCB brakes, air guides (brakeair spoiler) are also mounted on the rear suspension! These air guides are not mounted during transport! CAUTION Damaged, worn or missing aerodynamic components such as spoilers or underside panels affect the driving behaviour 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 guides

1. Mount the air guide (brakeair spoiler) on the front control arm (clip in similar to the standard air spoiler on the Carrera 996 and Turbo 996). Then insert the expansion rivet (included in the scope of delivery) into the bore present arrow . In vehicles with the model year 01, the bore arrow must also be drilled in the wheel housing liner behind (drill 8mm through the existing bore). 2. Mount the air guide in the same manner on the other side of the vehicle. top of page

Installing rear air guides

01 Installing air guides for PCCB brake discs GT2

1804

einordnung

1. Push air guide (brakeair spoiler) onto the lower rear axle control arm from the front.

Subsequently fit the retaining clip 2 (included in the scope of delivery) from the rear. The retaining clip 2 must be inserted into the slot of the air guide arrow at the top. Connect the retaining 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 behind). Note The illustration shows the rear of the air guide 1 (removed)! The left and right air guide 1 and retaining clip 2 differ from eachother! 2. Mount the air guide in the same manner on the other side of the vehicle.

996840, 996841

Installing rear air guides

1805

01 Fitting front lip

GT2

The 911 GT2 is lowered by approx. 30 mm as standard to lower the centre of gravity of the vehicle. The front lip is not fitted on the vehicle for protection when loading or unloading the vehicle. The front spoiler and fastening 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 locking tabs have engaged. 2. Place the sheetmetal nut 5 in position on the front end. Use the fastening screws 4 and spacer sleeves 3 to tighten the front spoiler at the sides to the wheel housing liner 2 .

996840, 996841

01 Fitting front lip

GT2

1806

01 Fitting sixpoint seat belt

GT2

The sixpoint seat belt is not fitted on vehicle delivery for the Club Sport equipment.

1. Loop technique for fastening the seat belt to the bucket seat cross member Loop the belt strap in the direction of the arrow inset around the front transverse strut on the bucket seat into the adjustible slider. The projection dimension = X of the belt strap must be at least 100 mm.

2. Pulling sixpoint seat belt through the openings in the bucket seat Pull sixpoint 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 belt fitting 5 at the left and right on the seat frame. With the shim 3 and the fastening screw 2 , screw the belt fitting 5 tight. Position the cover 1 on the fastening screw 2 . Use the foam part 4 for the Club Sport version. For the Cup racing version, mount the bushing 6 instead of the foam part. Tightening torque: 50 Nm (37 ftlb.)

01 Fitting sixpoint seat belt

GT2

1807

einordnung

4. Loop technique for fastening the seat belt to the bucket seat cross member a. Loop the belt strap in 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 belt strap and bind it with a tie wrap 1 .

996840, 996841

01 Fitting sixpoint seat belt

GT2

1808

01 Checking the Vehicle Ident. No.

Check that the Vehicle Ident. No. is correct. Check the Vehicle Ident. No. on the lower left windscreen in direction of travel. Check the Vehicle Ident. No. in the front right luggage compartment. Check the Vehicle Ident. No. on the data bank selfadhesive label in front inner cover. Stick the lower data bank selfadhesive label on the front inner cover in the onboard literature (Guarantee and Maintenance booklet). Check the Vehicle Ident. No. in the vehicle registration documents.

996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631, 996840, 996841

01 Checking the Vehicle Ident. No.

1809

01 Checking the exterior equipment and paint finish

Checking exterior equipment Checking paint finish 1. Visual inspection for film residue when removing the transport protection top of page

Checking exterior equipment

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, scratches, notches, scrapes, pores, bubbles, distinguishing marks in paint.

996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631, 996840, 996841

01 Checking the exterior equipment and paint finish

1810

01 Completing vehicle and checking equipment for completeness

Note Checking vehicle equipment for completeness Completing the vehicle Note Countryspecific equipment can be obtained from the relevant national importer!

top of page

Checking vehicle equipment for completeness

Allocation Designation 911 (996) 911 C4S (996) Countryspecific Turbo GT2 Coupe Cabrio Coupe Cabrio Japan Europe Germany X X X X X X X X X X X X X X X X => Tools X X X X X X X X X X X X X X X X X X X X => Completing the vehicle X X X X X X

Warning triangle Emergency kit Tool case Tools Socket for security wheel bolts Car jack Vehicle key set Flare and flare holder Onboard information folder with technical contents Driver's Manual, PCM/CDR, Guarantee and Maintenance booklet Windstop Collapsible wheel Compressor Sealant surface for tyres

X X

X X

X X

Tools

01 Completing vehicle and checking equipment for completeness

1811

einordnung Allocation 911 (996) 911 C4S (996) Turbo GT2 Coupe Cabrio Coupe Cabrio Openended wrench X X X X X Towing lug X X X X X Screwdriver X X X X X Plastic gloves X X X X X Socket wrench for fitting main headlight X X X X X Assembly aid for mounting wheels (aluminium bar with threads) X X X X X Pipe socket wrench X X X X Lever bar X X X X Plastic bag X X X X Two assembly aids for mounting wheels (aluminium bar with X X X threads) for vehicles with Ceramic Composite Brakes Allen socket wrench for emergency unlocking under the trim X X operating buttons for sliding roof Allen socket wrench for emergency unlocking behind the rear X X emergency seat trim Designation

top of page

Completing the vehicle

Onboard information folder with technical contents (Driver's Manual, Guarantee and Maintenance booklet) are supplied by dealers or importers, except in Germanspeaking countries. PCM/CDR operating instructions and Navigation CD are supplied by dealers or importers, except in Germanspeaking countries.

996420, 996421, 996450, 996451, 996430, 996431, 996620, 996621, 996650, 996651, 996630, 996631, 996840, 996841

Tools

1812

3 Technical Data GT2

6speed manual transmission G 96.88 top of page

6speed manual transmission G 96.88

Type G 96.88

Code letter

Equipment 6speed

Installed in GT2 (996)

Model year 2001

General data Transmission ratios 1. gear 2. gear 3. gear 4. gear 5. gear 6. gear Reverse gear Final drive Transmission ratio, final drive Filling capacity for new filling Change quantity

Manual transmission G 96.50 Z1 : Z2 = Z2 : Z1 11 : 42 = 3.82 21 : 43 = 2.05 27 : 38 = 1.41 34 : 38 = 1.12 37 : 34 = 0.92 40 : 30 = 0.75 14 : 40 = 2.86 Hypoid bevel gear drive with 10 mm offset 9 : 31 = 3.44 3.7 l + 0.1 l 3.7 l + 0.1 l

3 Technical Data GT2

1813

einordnung

Manual transmission tightening torques

Location Drain plug for transmission oil Filler plug for transmission oil Transmission on engine Air flanges on transmission Bracket for clutch control shaft on transmission Guide tube for release bearing on transmission housing Transmission support to transmission mount Transmission support to body Collar nut/halfshaft flange

Thread Tightening torque Nm (ftlb.) M22 x 1.5 30 (22 ftlb.) M22 x 1.5 30 (22 ftlb.) M10 45 (33 ftlb.) M6 10 (7.5 ftlb.) M6 x 16 10 (7.5 ftlb.) M6x14 10 (7.5 ftlb.) M10 65 (48 ftlb.) M10 65 (48 ftlb.) M20 x 1.5 120 (88.5 ftlb.)

996840, 996841

Manual transmission tightening torques

1814

4 Running gear, general GT2

General top of page

General
The 911 GT2 is available in the road version M002 and in a Club Sport version M003. The vehicle height of both designs (M002 and M003) is approx. 20 mm less than the 911 Turbo (996). The 911 GT2 differs from the 911 Turbo (996) through a newly shaped front end with enlarged air inlet openings for the chilledair supply of the radiators and of the frontwheel brakes. Moreover, the 911 GT2 is equipped with a large, nonretractable rear spoiler. The rear spoiler has a manually adjustable spoiler wing. The Club Sport design (M 003) possesses a removable roll cage. The roll cage includes the spring strut supports on the rear axle for stability. This further improves precise guidance of the rear wheels.

4 Running gear, general GT2

1815

einordnung The 911 GT2 is equipped as standard with the new Porsche Ceramic Composite Brake (PCCB). The brake calipers, 6piston on the front axle and 4piston on the rear axle, are painted yellow. The running gear of the 911 GT2 has been designed for an extremely sporty driving behaviour and superior handling properties. Basically, the running gear of the 911 GT3 (996) has been taken over and adapted to the specific new requirements (vehicle weight and driving performance). Moreover, the GT2 is subject to special demands due to the possibility of its use for racing purposes. These include: Lowering of the vehicle's centre of gravity with coordinated adjustment of the kinematics Adjustable stabilizers Extension of the 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 use of racing tyres (on the racing track) Optimisation of wheel guides (especially rear axle). Note The 911 GT2 is delivered with a runninggear setting coordinated with the tyres approved by Porsche! If these setting values are changed in a manner only permissible for use on racing tracks, it is essential that the standard settings are reset before the vehicle is driven on public roads! Attention: The adjustable spoiler (additional wing) is set to the lowest (horizontal) position for street use! Changes to the setting to match the personal driving style are intended only for the racing track!

The spoiler wing must be moved to the lowest position for use on public roads!

996840, 996841

General

1816

4 Notes on repair instructions GT2

General Tightening torques Adjustment operations on the spring struts Suspension alignment Wheel removal/installation Brake General Brake booster top of page

General
The 911 Turbo (996), and also the 911 GT2, is the basic model covered by the repair, assembly and adjustment operations in the "911 Carrera (996)" Technical Manual. Only the GT2specific procedures which deviate from this are additionally described in this Technical Manual. top of page

Tightening torques
Tightening torques for the 911 Turbo (996) and 911 GT2 are almost the same. Tightening torques that deviate or are additional are contained in the tables of the appropriate Repair Group for the 911 Turbo (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 secured against turning by the lock nut 1 . The stabilizer block (mounting saddle for the stabilizer mount) 4 is also fitted on the thread. The stabilizer block can be vertically 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 for deviating vehicle heights (only for racing) and also that the stabilizer mount can be fitted free of tension. The stabilizer block 4 does not need to be adjusted for the vehicle height prescribed for street use. The stabilizer block is also adjusted for replacement dampers.

Front axle 1. Lock nut 4 Notes on repair instructions GT2 1817

einordnung 2. Height adjusting nut 3. Lock nut 4. Stabilizer block

Rear axle 1. Lock nut 2. Height adjusting nut 3. Lock nut 4. Stabilizer block Note The special tool 9647 is required together with a torque wrench in order to adjust the vehicle height! Description under 911 GT2 suspension alignment in Repair Group 44. The stabilizer block is also adjusted for replacement dampers!

top of page

Suspension alignment
The adjustment procedures and 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 suspension alignment of the 911 Turbo (996). top of page

Wheel removal/installation
As the GT2 is equipped with PCCB (Porsche Ceramic Composite Brake), use assembly aids (assembly pins) for wheel removal/installation, in order to exclude any possibility of heavy contact of the wheel with the brake disc! The assembly aids (2 assembly pins) are located in the luggage compartment!

Adjustment operations on the spring struts

1818

einordnung

Screw the 2 assembly aids (assembly pins), instead of 2 wheel bolts, into the wheel hub. During removal, first remove the 3 remaining wheel bolts and remove the wheel carefully, without touching the brake discs! top of page

Brake General
The brake fluid change is the same as with the 911 Turbo (996). Bleeding of the GT2 is described in a new chapter. The 911 GT2 is equipped as standard with the new Porsche Ceramic Composite Brake (PCCB). The brake calipers, 6piston on the front axle and 4piston on the rear axle, are painted yellow. The GT2 is equipped with 3channel ABS (ABS 5.3) without PSM and without TC (Traction Control). Because of the larger brakedisc diameter in the PCCB, the fastening screws of the frontaxle and rearaxle brake calipers are 85 mm long and goldcoloured to differentiate them. top of page

Brake booster
When replacing the brake booster, observe the correct allocation according to the Spare Parts catalogue! Altered transmission ratio (boost factor) compared to the 911 Turbo (996). Boost factor 911 GT2 = 3.15 : 1. Boost factor 911 Turbo (996) = 3.85 : 1.

996840, 996841

Wheel removal/installation

1819

4 Tests / notes
Note Lifting platform / test stands Wheel alignment platform Brake test Power test Front and rear stabilizer setting Spoiler setting Racing camber values top of page

GT2

Note
The tests and notes apply to the street version (base version) M002 and to the Club Sport version M003. Suspension alignment 911 GT2 see Repair Group 44. top of page

Lifting platform / test stands

Ensure clearance of the spoiler(s) and side members when driving 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 aids, are used! A platform without a sloped position is unsuitable! top of page

Brake test
Brake tests can only be carried out on rollertype test stands or plate test stands. When driving onto the brake test stand, make sure to drive on as carefully as possible, especially during compression. This helps to prevent the vehicle from bottoming out. top of page

Power test
A power test is not permissible or possible! top of page

4 Tests / notes

GT2

1820

einordnung

Front and rear stabilizer setting

CAUTION There will be alterations in the handling if the stabilizer standard setting is changed! The standard setting must not be changed for use on public roads! Attention: Changes to the setting to match the personal driving style racing track!

are permissible only for the

The front and rear stabilizers can be individually adjusted by means of 5 bores at the front and 4 bores at the rear.

The front stabilizer with 26.8 x 4 mm diameter was adjusted (fitted) at the production launch to the center position (position 3). This setting was modified in the current model year 2002. New/current 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 (fitted) to the second hardest position (third bore) arrow . This standard setting must not be changed for use on public roads! Attention: Changes to the setting to match the personal driving style are permissible only for the racing track! Adjustment/fitting of the GT2 road version: GT2 = 3rd bore arrow (GT3 = 2nd bore). top of page

Spoiler setting
The spoiler wing is set to the lowest (horizontal) position for street use! Changes to the setting are only intended for the racing track. The spoiler wing must be moved to the lowest position for use on public roads!

top of page Front and rear stabilizer setting 1821

einordnung

Racing camber values

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

Racing camber values

1822

44 Alignment card GT2

Porsche measurement of running gear Customer: Street: Place: Telephone: Measurement made by: Vehicle: 911 GT2 (996) M002 and M003 Measurement prerequisite (vehicle weight): This includes: full fuel tank and vehicle with tools. Reason for measurement: Make of tires: Size/model at front: front left Tire pressure of cold tires (bar) Tire/wheel (any damage) Tires tread depth (mm) Rep. Order No.: Vehicle Ident No.: Licence number: Date of first registration: Odometer reading: km/miles Date / signature: Model: Empty weight as in DIN 70020.

Rear: front right rear left rear right

Incoming measurement Nominal values/ (max. Difference, left/right ) Vehicle height: Front (mm) Rear (mm) Rear axle: Camber Toe left/right left/right left/right left/right total Driveaxle angle Front axle: Caster 1 50' 5' / (max.10' ) + 13' 2' / (max. 5' ) + 26' 4' 0 00' 5' 8 30' / (max.40' ) 1 50' 30' 1 50' 30' 1 5' / (max. 10' ) + 4' 1' + 8' 2'

Outgoing measurement

left/right

Toedifference angle left right Camber left/right Toe left/right total

44 Alignment card GT2

1823

einordnung Since mainly electronic wheelalignment testers in conjunction with printers are used, a specimen alignment card is rarely required nowadays. In order for measured results to be documented in individual cases, however, a copy of the alignment card shown above can be used. Note In practice this means that alignment cards cannot be ordered! The alignment cards can be used for all 911 GT2 (996), M002 = street vehicle 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 alignment card. Note Actual values that are identical in all versions have already been entered! 3. Enter the appropriate version, e.g. M002 or M003, in the Model column. 4. Carry out incoming measurement (actual state) and enter the values in the alignment card! 5. After adjustments (if these were necessary), enter the actual values in the column Outgoing measurement.

996840, 996841

44 Alignment card GT2

1824

Suspension alignment GT2

Suspension alignment, complete Driving onto measuring platform Tools Deviating points for GT2 Notes on height changes/wheelload changes Vehicle height GT2 Wheel alignment Instructions for fitting diagonal control arm on control arm top of page

GT2

Suspension alignment, complete

Note The 911 GT2 suspension alignment contains only those procedures which deviate from those for the 911 Turbo (996) suspension alignment.

top of page

Driving onto measuring platform

Due to the reduced vehicle height, additional access 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 position is unsuitable. top of page

Tools
The special tools for suspension alignment of the 911 Turbo (996) are also used for the 911 GT2. Additionally, a hook wrench insert (special tool 9647) is required for the 911 GT2. The special tool 9647 is required to change the vehicle height and to adjust the stabilizer mating bearing on the front and rear axle. The special tool is used together with a torque wrench to tighten the lock nuts (slotted nuts) on the spring struts. Tightening torques in Repair Group 40/42.

Suspension alignment GT2

1825

einordnung

Special tool 9647

top of page

Deviating points for GT2

In the description of the 911 GT2 suspension alignment, only those points are listed which differ from the 911 Turbo (996). These are: Changed adjustment values. Frontaxle camber setting: Unlike the 911 Turbo (996), a basic camber adjustment is made by means of intermediate plates on the 2part control arm of the front axle for the 911 GT2. A 1 mm thick adjustment plate is fitted as standard on the right and left in the 911 GT2 (M002 and M003)! Camber adjustment (fine adjustment) is carried out at the springstrut mount as for the 911 Turbo (996). For the measuredvalue pickups, electronic wheel alignment testers require spoiler adapters of 50 mm and 100 mm in length, 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 measuring program require 100 mm spoiler adapters on the rear axle. Observe the operating instructions from manufacturer of the measuring instrument if necessary! In the case of the 911 GT2, the vehicle height can be adjusted on the front and rear axle using the adjusting nut(s) at the corresponding spring strut(s). Max. wheelload difference to right and left on the front and rear axle is 15 kg. Check all wheels for clearance after adjustment and assembly work! Note If a wheel removal is necessary, 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) are located in the luggage compartment!

Tools

1826

einordnung

Screw the 2 assembly aids (assembly pins), instead of 2 wheel bolts, into the wheel hub before wheel removal/installation! During removal, first remove the 3 remaining wheel bolts and remove the wheel carefully, without touching the brake discs!

top of page

Notes on height changes/wheelload changes

When changing the height/wheel load, the following must be noted: A onesided height change causes a wheelload change at the same time. A wheelload change on one wheel also alters the wheel loads of the other wheels. A onesided increase in the installed spring preload (raising vehicle) increases the wheel load. A onesided decrease in the installed spring preload (lowering vehicle) decreases the wheel load. A change in the wheelload is always transferred diagonally onto the other axle side. This means that if the wheel load on one wheel is decreased or increased, the same occurs on the diagonally opposite wheel. Maximum wheelload difference from left to right on front and rear axle 15 kg.

Example: Rear left spring preload C is increased. In this way the wheel load: rear left C and front right B greater rear right D and front left A less.

top of page

Deviating points for GT2

1827

einordnung

Vehicle height GT2

The vehicle height on the front and rear axle of the 911 GT2 can be adjusted. Before wheel alignment values are adjusted at front and rear axles, it is recommended or necessary that the height adjustment be checked at the DIN empty weight. The height adjustment possibility allows the wheelload difference from right to left to be kept as small as possible, provided that wheel load weighing machines are available. The wheelload difference is adjusted by changing the vehicle height within the height tolerance. The priority is to achieve the smallest possible wheelload difference from left to right. The height adjustment possibility allows: Differing wheel loads on left and right to be corrected. At the correct height the wheelload 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. Wheelload differences can be kept as low as possible in conjunction with wheelload weighing machines. Tolerance from right to left on front and rear axle under 15 kg. Any impermissible height differences front axle to rear axle can be balanced out (only within the permissible tolerance). For the height check of the readytodrive vehicle (full tank and tools), place the vehicle on a level surface or on the measuring platform. Front axle: Measure from road contact surface to the lower edge of the hexagonhead bolt of the tensionstrut screw connection to the body. Measuring point as with 911 Turbo (996).

Front axle Rear axle: Measure from wheel contact surface to the locating bore in the rearaxle side section (between toe and camber eccentrics).

Rear axle Note

Vehicle height GT2

1828

einordnung Required values for front and rear axle can be found in the table "Adjusting values for suspension alignment"! The vehicle height on the front and rear axle is adjusted by turning the adjusting nut No. 2 . The lock nut No. 1 must first be loosened. Use a hook wrench or special tool 9647 (hook wrench insert) for this purpose. Adjusting nut No. 2 turn to the right = vehicle higher turn to the left = vehicle lower After adjustment of the lock nut(s) No. 1 on the front and rear axle, tighten 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 Group 44. After adjustment, tighten the appropriate screwed connections with the prescribed tightening torque. See tables in Rep. Gr. 40 and 42.

Front axle 1 Lock nut 2 Height adjusting nut

Rear axle 1 Lock nut 2 Height adjusting nut top of page

Wheel alignment
Note In the 911 GT2, ABS (without PSM) is used as a control system! After the wheelalignment values are changed, the PSMrelated work is therefore omitted in contrast to the 911 Turbo (996)! Wheel alignment 1829

einordnung

Frontaxle camber setting

Note Frontaxle camber setting: Unlike the 911 Turbo (996), a basic camber adjustment is made by means of intermediate plates arrow on the 2part control arm of the front axle for the 911 GT2. A 1 mm thick adjustment plate is fitted as standard on the right and left in the 911 GT2 (M002 and M003)! Check all wheels for clearance after adjustment and assembly work!

Control arm GT2 Basic camber setting through adjustment plates arrow series = one 1 mmthick adjustment plate By using thicker adjusting shims, the 2part control arms permit a correspondingly increased camber value to be obtained for circuit use. In relation to this, observe also the note on the fitting of the diagonal control arm to the control arm GT2 => Instructions for fitting diagonal control arm on control arm &ndash; GT2

Camber fine adjustment

The camber is adjusted by moving the spring strut transversely. For this purpose, loosen the three M8 fastening nuts arrows of the springstrut mount. To shift the spring strut inwards or outwards arrows , remove the cover cap over the piston rod!

Frontaxle camber setting

1830

einordnung

Camber/toe, rear axle

As with the 911 Turbo (996), the wheelalignment values on the rear axle are set at the toe eccentric A and at the camber eccentric B . top of page

Instructions for fitting 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 arm, left A C 1 2 Control arm, left Direction of travel Centre bore for GT2 road model Rear bore only for Cup vehicle (with racing circuit camber values)

Camber/toe, rear axle

1831

einordnung

Control arm, right B C 1 2 Control arm, right Direction of travel Centre bore for GT2 road model Rear bore only for Cup vehicle (with racing circuit camber values)

996840, 996841

Instructions for fitting diagonal control arm on control arm GT2

1832

44 Tyre failure / tyre sealant

Note Repair procedure Note

GT2

The 911 GT2 is delivered with a tyre repair kit! A spare wheel or emergency wheel is not available! The tyre repair kit (Tire Mobility System), a compressor and a pressure tester are located in the luggage compartment! It is essential to observe the safety and operating instructions on the sealant bottle and on the compressor! Sealing the tyre with the tyre repair kit is only an emergency repair! Even if the tyre is sealed, it may only be used for short journeys in the event of an emergency and must be replaced by a professional workshop immediately! Avoid sharp acceleration and high speed on bends! The highest permissible speed is 80 km/h!

top of page

Repair procedure
1. Take out sealant bottle and compressor. Shake sealant bottle well. 2. Screw the accompanying filler hose onto the bottle. The foil on the closure 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 sealing plug from the filler hose, push the hose onto the tyre valve. 5. Hold the bottle with its base upwards and empty the entire contents of the bottle into the tyre. Then remove the hose and screw the valve insert tightly into the tyre valve again. CAUTION Damage to the compressor (danger of overheating) in the case of excessively long operation! Do not operate the compressor for longer than 6 minutes! 6. Screw the filler hose of the compressor onto the tyre valve, insert the plug into the cigarette lighter. Pump tyre to 2.0 2.5 bar (read off pressure on pressure gauge). 7. If this air pressure cannot be reached, drive approx. 10 metres forward or backward with the vehicle, so that the sealant can distribute itself in the tyre. Repeat pumping procedure. Note If the required air pressure still cannot be reached, the tyre is too badly damaged! 44 Tyre failure / tyre sealant GT2 1833

einordnung In this case, Tirefit cannot provide the required sealing! If the tyre pressure has fallen to below 1.3 bar, do not travel any further! Danger of accident! If more than 1.3 bar is measured, adjust the air pressure 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 the journey immediately with care at max. 80 km/h. 10. Check the tyre pressure after driving for 10 minutes (use service station or pressure gauge of the compressor).

996840, 996841

Repair procedure

1834

46 Technical data/Brake wear limit GT2

Technical Data GT2 Wear limit technical Data GT2 top of page

Technical Data GT2

The first GT2 vehicles will start without PCCB. Instead of this a conventional braking system will be installed with the following deviating specification: 6piston front fixed caliper, 4piston rear fixed caliper Front and rear fixed caliper painted yellow / front fixed caliper, identical part to PCCB Other front and rear brake pads (brake pad version) as for PCCB 350 mm cast iron front brake discs 330 mm cast iron rear brake discs

Designation Operating brake (foot brake) with ceramic brake discs (production launch with cast iron brake discs)

Brake booster (vacuum) Boost ratio Brake master cylinder

Notes, dimensions Wear limit Hydraulic dualcircuit brake system with frontaxle / rearaxle brakecircuit distribution. Vacuum brake booster, internally ventilated and perforated brake discs with sixpiston monobloc fixed caliper on the front axle and fourpiston monobloc fixed caliper on the rear axle. The brake calipers are painted yellow for visual differentiation. ABS 5.3 with CANBus (3channel ABS without PSM and without TC (Traction Control). 10 inch 3.15 25.4 mm 25.4 mm 18/18 mm excluding PCCB = 350 mm steel = 350 mm PCCB = 350 mm steel = 330 mm PCCB and steel 284 mm PCCB 291 mm steel 271.2 mm

front rear Stroke front rear

Brake proportioning control Brake discs

Effective brake discs

front rear

46 Technical data/Brake wear limit GT2

1835

einordnung Piston in brake caliper front 6piston rear 4piston front rear 2 x 38 mm 2 x 32 mm 2 x 28 mm 2 x 30 + 2 x 28 mm 448 cm2 248 cm2 696 cm2

Brake pad area Total brake pad area

top of page

Wear limit technical Data GT2

Two condition criteria can make replacement necessary depending on the wear of PCCB brake discs: 1. Surface changes in the brake disc friction surfaces at an advanced stage. 2. Brake disc minimum thickness is not attained due to wear (material erosion due to friction). Designation Pad thickness Brake disc thickness, new Brake discs minimum thickness Note, dimensions Wear limit front approx. 12.0 mm 2 mm rear approx. 12.0 mm 2 mm front 34 mm rear 28 mm front PCCB = 33.5 mm steel = 32.0 mm rear PCCB = 27.5 mm steel = 26.0 mm 0.02 mm 0.03 mm 0.03 mm 0.06 mm approx. 1 mm Drum brake acting mechanically on both rear wheels 180 mm 181 mm 25 mm 4.5 mm 2 mm

Thickness tolerance of the brake discs, max. Lateral runout of the brake disc, max. Lateral runout of the wheel hub, max. Lateral runout of the brake disc when installed, max. Pushrod play (measured at the brake pedal plate) Parking brake (handbrake) Parking brake drum Brake shoe width Brake pad thickness

996840, 996841

Technical Data GT2

1836

40 Disassembling and assembling front spring strut GT2

Notes about adjustment work on the spring struts Disassembling and assembling front spring strut GT2 Disassembly and assembly instructions top of page

Notes about adjustment work on the spring struts

The spring strut has a thread and a height adjusting nut 2 for height adjustment. The height adjusting nut 2 is secured against turning by the lock nut 1 . The stabilizer block 4 (mounting saddle for the stabilizer mount) is also fitted on the thread. The stabilizer block 4 can be vertically adjusted and it is provided with a lock nut 3 . This 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 the stabilizer mount can be fitted free of tension. The stabilizer block 4 does not need to be adjusted for the vehicle height prescribed for street use. The stabilizer block 4 , dimension B is also set with replacement dampers. 1 Lock nut 2 Height adjusting nut 3 Lock nut 4 Stabilizer block A Presetting dimension for production (289 mm). The dimension may be different with the prescribed vehicle height. If the damper is replaced, the actual dimension must be transferred to the new damper. B Dimension = 198 mm (plus/minus 0.5 mm) top of page

40 Disassembling and assembling front spring strut

GT2

1837

einordnung

Disassembling and assembling front spring strut

GT2

No. Designation Qty. Removal Installation 1 Fastening nut 1 If necessary, pretension with the spring clamp Use new fastening nut. M 14 x 1 before loosening the fastening nut. This depends Grease thread of the piston on the adjustment (pretension) of the coil rod with Optimoly HT spring. Support at the piston rod with a (copper paste). Tighten to countering tool Sonderwerkzeug 9630 or a 7 mm 80 Nm (59 ftlb.) Allen key when loosening the nut. 2 Assembly of 1 Remove complete assembly (consisting of No. 8 The spring strut mounts for spring strut / No. 9 / No. 10 / No. 11). the right and left sides are mount identical parts. 3 Spring mount 1

Disassembling and assembling front spring strut

GT2

1838

einordnung 4 5 6 Rubber support Bellows Coil spring 1 1 1 Replace if necessary

Vibration damper

8 9

Spacer sleeve Retainer spring 10 Protective bellows 11 Spring strut mount

1 1 1 1

Available as spare part only in sets. Mount in correct position (tighter winding downwards). The coil spring is fitted with a protective sheath on one side. The vibration dampers for the right and left sides are identical parts Mount in correct position. Mount on protective bellows (No. 10)

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. Manufacturer: AutolWerke Paradiesstr. 14 D97080 Wrzburg

top of page

Disassembly and assembly instructions

Disassembly
CAUTION Danger of injury due to spring tensioning! If necessary, tension the coil spring with the spring clamp until the piston rod is relieved! Never use an impact bolter to loosen or tighten the fastening nut! Use commercially available changeover ratchet! 1. Disassembly and assembly instructions 1839

einordnung If necessary, tension the coil spring with the spring clamp until the piston rod is relieved. To undo the connection piston rod to spring strut mount counter at the piston rod with countering tool Sonderwerkzeug 9630 or a 7mm Allen key. 2. Remove all parts from the piston rod.

Preliminary work and notes on assembly

If the vibration damper is to be replaced, set the height adjusting nut 2 to the same position as on the old vibration damper (transfer the actual dimension A 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 not be adjusted for street use!

The hook wrench Sonderwerkzeug 9647 is required for changing the vehicle height (dimension A) and for adjusting the stabilizer mating bearing (dimension B). The special tool is used together with a torque wrench to tighten the lock nuts (slotted nuts) on the spring struts.

Assembly
Note When installing new parts, observe the allocation according to the Spare Parts Catalogue! The coil springs are only available in pairs! Disassembly 1840

einordnung

1. Push coil spring 6 , spring plate 3 with rubber ring 4 and bellows 5 onto the vibration damper. The tighter winding of the coil spring 6 must face down towards the damper tube 7 . Note The coil spring is fitted with a protective sheath on one side! 2. Grease thread of the piston rod with Optimoly HT (copper 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 identical parts! In the case of used mounts, the bearing shell can be regreased with Autol Top 2000! Manufacturer: AutolWerke, Paradiesstr. 14, D97080 Wrzburg. Replace nut for fastening the piston rod on the spring strut mount! Never use an impact bolter to tighten the fastening nut!

Assembly

1841

einordnung

4. Turn new fastening nut on the piston rod and tighten to 80 Nm (59 ftlb.). Use 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 Sonderwerkzeug 9630 or a 7 mm Allen key.

996840, 996841

Assembly

1842

42 Disassembling and assembling rear spring strut GT2

Notes about adjustment work on the spring struts Disassembling and assembling rear spring strut GT2 Disassembly and assembly instructions top of page

Notes about adjustment work on the spring struts

The spring strut has a thread and a height adjusting nut 1 for height adjustment. The height adjusting nut 1 is secured against turning by the lock nut 2 . The stabilizer block 4 (mounting saddle for the stabilizer mount) is also fitted on the thread. The stabilizer block 4 can be vertically 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 for deviating vehicle heights (only for racing) and also that the stabilizer mount can be fitted free of tension. The stabilizer block 4 does not need to be adjusted for the vehicle height prescribed for street use! A Presetting dimension for production (176 mm). The dimension may be different with the prescribed vehicle height. B Dimension B = 105 mm (plus/minus 1 mm) C Dimension C = 90 degrees

The mounting saddle is also set with replacement dampers (dimension B and dimension C)! 42 Disassembling and assembling rear spring strut GT2 1843

einordnung

top of page

Disassembling and assembling rear spring strut GT2

No. 1

Designation Fastening nut M 12 x 1.5

Qty. 1

Removal If necessary, pretension the coil spring with the spring clamp before loosening the fastening nut. This depends on the pretension of the coil spring. Support at the piston rod with a countering tool Sonderwerkzeug 9630 or an openended wrench (7mm) when loosening the nut.

Installation Use new fastening nut. Tighten to 60 Nm (44 ftlb.). Position the spring strut mount No. 3 first (see under assembly instructions). 1844

Notes about adjustment work on the spring struts

einordnung 2 Washer (stop plate) 1 Mount in correct position. No. 2 and No. 7 are identical parts. The mounts for the right and left sides are identical parts. Position the mount before tightening the fastening nut No.1 (see under assembly instructions). Renew if necessary. Also fit on vehicles, model '01 (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 model '02 (2). On vehicles of model '01 (1), mount (fit) the protective sheath at the top and bottom in the area of the contact points of both spring ends! Mount in correct position (No. 2 and No. 7 are identical parts).

Spring strut mount

Support ring 1 (rubber washer)

Standard as of model '02 (2)

5 6

Spring plate Coil spring

1 1

Washer (stop plate)

8 9 10

Washer Additional spring Vibration damper

1 1 1 Observe allocation as per Spare Parts 1845

Disassembling and assembling rear spring strut GT2

einordnung Catalogue. The vibration dampers for the right and left sides are identical parts.

top of page

Disassembly and assembly instructions

Disassembly
CAUTION Danger of injury due to spring tensioning! If necessary, tension the coil spring (depending on the spring preload) with the spring clamp until the piston rod is relieved! Never use an impact bolter to loosen or tighten the fastening nut! Use commercially available changeover ratchet! 1. If necessary, tension the coil spring (depending 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 Sonderwerkzeug 9630 or an openended wrench (7 mm). 3. Remove all parts from the piston rod.

Preliminary work and notes on assembly

If the vibration damper is to be replaced, set the height adjusting nut 1 to the same position as on the old vibration damper (transfer the actual dimension A to the new vibration damper). A hook wrench insert, special tool 9647 is required for this purpose. Tightening torque of the lock nuts 2+3 = 50 Nm (37 ftlb.)! Disassembly and assembly instructions 1846

einordnung The stabilizer mating bearing (mounting saddle) 4 need not be adjusted for street use.

The hook wrench insert Sonderwerkzeug 9647 is required to change the vehicle height and to adjust the stabilizer mating bearing on the front and 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 plate in correct position) as far as they will go on the piston rod. 2. Place coil spring 6 in the correct position, tighter winding facing down, onto the vibration damper.

Note

Preliminary work and notes on assembly

1847

einordnung The coil spring 6 is fitted as standard with a protective sheath arrows at the top and bottom on vehicles as of model '02 (2). On vehicles of model '01 (1), mount (fit) the protective sheath at the top and bottom arrows in the area of the contact points of both spring ends. 3. Fit spring plate (spring retainer), support ring (rubber washer) and spring strut mount onto the coil spring. Note If the support ring (rubber washer) is not yet available, fit the rubber washer on vehicles of model '01 (1)! 4. Place stop plate in the correct position 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 fastening nut. Note The spring strut mount for the right and left sides are identical parts!

The spring strut mount is positioned correctly if one of the 3 fastening pins is aligned with the stabilizer mounting saddle! 6. Position the spring strut mount for installation (correctly position spring strut mount with respect to the damper). 7. Once the mount has been positioned correctly, tighten the fastening nut. Tightening torque 60 Nm (44 ftlb.). Note Never use an impact bolter to tighten the fastening nut! Assembly 1848

einordnung 8. When tightening the fastening nut, hold at the piston rod using a countering tool Sonderwerkzeug 9630 or a 7 mm openended wrench.

996840, 996841

Assembly

1849

30 01 07 Bleeding the clutch system GT2

Note Filling/bleeding Note The clutch hydraulics must always be filled or bled using a pressure filling and bleeding device. Furthermore, the bleeder valve must be opened sufficiently and the gauge pressure must be approx. 2.0 bar. If there is no system pressure, before the system is filled or bled, the clutch pedal must be in the "Pedal fully depressed" position. In order to avoid risk of injury or damage, the pedal must be guided manually. Otherwise, the clutch pedal can move forward abruptly (as a result of servo kinematic effects). If the system was open previously (e.g. for component replacement), the minimum filling or bleeding time must be 30 seconds. Use only new Super DOT 4 brake 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.

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Filling/bleeding
DANGER Please note: danger of injury from depressing the clutch pedal, if there is no system pressure. The clutch pedal will move forward abruptly as a result of servo kinematic effects. If the clutch pedal is fully depressed, the pedal must be guided manually. 1. If there is no or only lower system pressure, depress the clutch pedal fully. Guide the clutch pedal manually.

2. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure is approximately 2.0 bar. 3. The bleeder valve from the clutch slave cylinder (on the transmission) must be opened until clear, bubblefree brake fluid emerges. Use a collecting bottle for precise examination of the emerging 30 01 07 Bleeding the clutch system GT2 1850

einordnung brake fluid for cleanliness and freedom from bubbles. If 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 necessary.

996840, 996841

Filling/bleeding

1851

30 45 19 Removing and installing release bearing (clutch removed) GT2

Removing release bearing Installing release bearing

No. Designation Qty. Removal 1 Snap ring 1 Remove using pointednose pliers, simultaneously push down pressure plate using a press. 2 Thrust plate 1

Installation Ensure correct seating

Check, do not wash out, just dry wipe

Engage lug (twist lock) in the opening of a diaphragm spring tongue Do not grease sliding surface 1852

30 45 19 Removing and installing release bearing (clutch removed) GT2

einordnung Release bearing Spring washer Spacer washer Thrust plate

4 5 6

1 2 1

Mount in correct position Fit 2 spacer washers Check for wear, replace if necessary

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Removing release bearing

1. The release bearing is removed 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 freely. 2. Remove snap ring and take out release bearing. top of page

Installing release bearing

Note

Do not grease the sliding surfaces of the release bearing and the guide tube.

Removing release bearing

1853

einordnung

Note

The guide sleeve of the release bearing is slotted. The slot is irregular.

1. Fit spacer washers and spring washers on the new release bearing. When doing so, ensure that 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 two tongues of the diaphragm spring. 3. Fit snap ring under the press. Ensure that the snap ring is seated correctly.

996840, 996841

Installing release bearing

1854

30 50 19 Removing and installing clutch GT2

Tools Removing clutch Installing clutch Tightening torques top of page

Tools

Item A B

Designation of the special tool Toothed segment P201b Centring mandrel 9102

Explanation

top of page

Removing clutch
1. Remove transmission 34 35 27 Removing and refitting the transmission.

30 50 19 Removing and installing clutch GT2

1855

einordnung

2. Position the toothed segment P201b A on the stud and undo the panhead screws in several stages and in diametrically opposite sequence, to avoid deforming the thrust plate. top of page

Installing clutch
1. Fit drive plate with centring mandrel, special tool centring mandrel 9102 in the guide bearing (needle bush).

2. Fit thrust plate. To do so, position the special tool toothed segment P201b A on the stud and tighten the panhead screws in several stages and in diametrically opposite sequence. Tightening torque: 23 Nm (17 ftlb.) 3. Remove the special tool centring mandrel 9102 . 4. Remove the special tool toothed segment P201b . 5. Refit transmission. 34 35 27 Removing and refitting the transmission. top of page

Tightening torques

Location Panhead screws thrust plate ZMS

Thread M8

Tightening torque Nm (ftlb.) 23 (17 ftlb.)

996840, 996841

Removing clutch

1856

30 50 37 Disassembling and assembling clutch GT2

No. Designation 1 Panhead screw M8

Release bearing Thrust plate Drive plate Doublemass flywheel

Qty. Removal 9 In order to avoid deformation of the thrust plate housing, loosen screws in several stages and in diametrically opposite sequence. 1

Fitting In order to avoid deformation of the thrust plate housing, tighten screws in several stages and in diametrically opposite sequence. Do not wash out the bearing; replace loud bearings; do not grease the sliding surface. Centre with centring mandrel 9102 . Ensure the centring pins are seated firmly.

3 4 5

1 1 1

996840, 996841

30 50 37 Disassembling and assembling clutch GT2

1857

34 01 55 Changing transmission oil GT2

Changing transmission oil GT2 Topping up transmission oil GT2 Tightening torques Total capacity: 3.7 + 0.1 Liter Oil change quantity: 3.7 + 0.1 Liter Note Use only oils approved for this type by Porsche. See Parts Catalogue.

top of page

Changing transmission oil GT2

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. Clean the drain plug and filler screw. 2. Screw in oil drain plug again and top up oil up to the bottom edge of the oil filler opening. Tightening torque: 30 Nm (22 ftlb.) 3. Screw in oil filler plug. Tightening torque: 30 Nm (22 ftlb.) 4. Fit underbody trim parts. top of page

34 01 55 Changing transmission oil GT2

1858

einordnung

Tightening torques

Location Oil filler plug Oil drain plug

Thread M22 x 1.5 M22 x 1.5

Tightening torque Nm (ftlb.) 30 (22 ftlb.) 30 (22 ftlb.)

996840, 996841

Tightening torques

1859

34 35 27 Removing and refitting the transmission GT2

Tools Removing transmission Refitting transmission Tightening torques top of page

Tools

Item Designation of the special Explanation tool A Gripper Commercially available Rep. Gr. Workshop Equipment Manual Chapter 2.4, No. 50 B Removal mandral Special tool 9287

top of page

Removing transmission
1. Remove enginetransmission unit 100119 . 2. Disengaging starter cable.

34 35 27 Removing and refitting the transmission GT2

1860

einordnung

3. Pull of vacuum line from coolant valve A .

4. Remove right air flanges, unscrew hexagonhead bolt A seated below them for holder and remove holder. 5. Remove bearing cover B with commercially available pliers Handbuch Werkstattausrstung 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 transmission from the engine. top of page

Refitting transmission
Note Grease teeth of the drive shaft with a very thin coat of Olista Longtime 3P (only as protection against corrosion).

Removing transmission

1861

einordnung

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 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 Hexagonhead bolt 2 Holder 3 Bearing cover 4 Needleroller bearing with assembly bore 5 Sealing ring 6 Clutch control shaft 7 Release lever Refitting transmission 1862

einordnung 5. Remove adhesive tape through the assembly opening in the release fork. 6. Fit bearing cover with special tool removal mandrel 9287 . 7. Fit holder for clutch control shaft. Tightening torque: 10 Nm (7.5 ftlb.) 8. Refit transmission on motor and screw in screws. Tightening 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 enginetransmission unit. 100119 . top of page

Tightening torques

Location Transmission on engine Air flanges on transmission Bracket for clutch control shaft on transmission

Thread M10 M6 M6 x 16

Tightening torque Nm (ftlb.) 65 Nm (48 ftlb.) 10 (7.5 ftlb.) 10 (7.5 ftlb.)

996840, 996841

Tightening torques

1863

34 37 37 Disassembling and assembling transmission housing GT2

Tools Overview Disassembly and assembly instructions Tightening torques top of page

Tools

Item A B C D E F G H I J K L M

Designation of the special tool Striker Protective sleeve Pressure piece Threaded piece Pressure piece Pressure piece Pressure piece Pressure pieces Pressure piece Pressure piece Socket wrench insert Pullin tool and extractor Mandrel

Explanation Special tool striker VW 771 Special tool protective sleeve 9649 Special tool pressure piece 9648/2 Special tool threaded piece VW 771/15 Special tool pressure piece P 254 b Special tool pressure piece 3062 Special tool pressure pieces 9247 Special tool pressure piece 9252 Special tool pressure piece VW 513 Special tool pressure piece 9649/1 Special tool socket wrench insert 9658 Special tool pullin tool and extractor P 254 Special tool mandrel 9515

34 37 37 Disassembling and assembling transmission housing GT2

1864

einordnung N O P Q Mandrel Drift Pressure piece Pressure piece Special tool mandrel VW 295 Special tool drift P 264 b Special tool pressure piece 9648/1 Special tool pressure piece 9648

top of page

Overview

No. Designation 1 Screw plug (with sealing ring) Tools

Qty. Removal 1

Installation Clean, tighten to 30 Nm (22 ftlb.). Replace sealing ring.

1865

einordnung 2 3 Shaft seal Shaft seal 1 1 Install only after fitting the gear set. Drive in shaft seal with pressure piece VW 513 as far as the mounting face. Fill the space between the dust and sealing lips with grease (e.g. Liqui Moly). Remove with special tool striker Drive in with special tool pressure piece VW 771 , special tool threaded 9648 . (Installation depth 0.6 mm). part VW 771/15 and a suitable internal puller. Drive out with aluminium or Drive in with special tool pressure piece copper mandrel, changing sides. 3062 and special tool mandrel VW 295 as far as the mounting face. Drive out from the inside with Drive in with special tool pressure pieces special tool pressure piece VW 9247 and special tool pullin tool and 513 . extractor P 254 . Drive out from the inside with Drive in with special tool pressure piece special tool drift P 264 b . P 254 b and special tool pullin tool and extractor P 254 . Fit in correct position and make sure it is seated properly. Use special tool protective sleeve 9649 . Insert in the correct position.

Ball sleeve

Outer bearing race Outer bearing race Outer bearing race Circlip Selector lever

8 9

1 1 1 1 1

10 Rubber washer 11 Selector lever 12 Shaft seal

13 Bushing 14 Shift pinion

2 1

Drive out with special tool pressure piece 9648/2 .

15 Adjusting shim X 16 Snap ring 1

Mark for refitting.

Drive in with special tool pressure piece 9649/1 . Fill the space between the dust and sealing lips with grease (e.g. Liqui Moly). Drive in with special tool pressure piece 9648/1 . Axial play 0 to 0.15 mm. Setting with shim (No.15). Remeasure if necessary. Push the snap ring and cap (no. 17) down until the snap ring engages into the groove.

17 Closure cap 1 18 Compression 1 spring 19 Bearing screw* 1

Remove with special tool socket Tighten to 50 Nm (37 ftlb.). wrench insert 9658 . Unscrew it only if the transmission has to be disassembled!

20 Swivel arm

Overview

1866

einordnung 21 Transmission housing 1

Note * Parts of the shifting mechanism will fall into the transmission if the bearing screw No. 23 is unscrewed.

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Disassembly and assembly instructions

Disassembly

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 selector lever and shift pinion in the correct position. (The driver cross is vertical and the selector lever reaches the flat surface of the housing.)

Disassembly and assembly instructions

1867

einordnung

2. Fit the retainer in the correct position and make sure it is seated properly. top of page

Tightening torques

Location Plug screw (no. 1 in overview) Bearing screw (no. 19 in overview)

Thread M22 x 1.5

Tightening torque Nm (ftlb.) 30 (22) 50 (37)

996840, 996841

Assembly

1868

34 52 37 Disassembling and assembling gear housing GT2

Tools Overview Disassembling gear housing Assembling gear housing Tightening torques top of page

Tools

Item Designation of the special tool A Striker B Pressure piece C Pressure piece D Mandrel E Threaded piece F Internal puller 14 20 mm G H J K Pressure piece Pressure piece Pressure piece Pressure piece

Explanation Special tool Striker VW 771 Special tool Pressure piece P 254 b Special tool Pressure piece P 254 a Special toolPullin tool and extractor P 254 Special tool Threaded piece VW 771/15 Commercially available Handbuch Werkstattausrstung Kapitel 2.4, Nr. 108 Special tool Pressure piece 9648/1 Special tool Pressure piece 9648 Special tool Pressure piece 9648/2 Special tool Pressure piece 9649/1

34 52 37 Disassembling and assembling gear housing GT2

1869

einordnung

top of page

Overview

No. 1 2 3 4 5 6 7 8 Tools

Designation Screw plug Snap ring Outer bearing race Snap ring Snap ring Outer bearing race Snap ring Ball sleeve

Qty. 1 1 1 1 1 1 1 1 1870

einordnung 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Ball sleeve Ball sleeve Ball sleeve Screw plug Compression spring Locking pin Circlip Shift lever Shift catch Roller Shaft seal Bearing sleeve Rubber washer Gear housing 1 1 1 1 1 1 1 1 1 1 1 2 1 1

top of page

Disassembling gear housing

1. Remove transmission cover. 2. Disassemble front gear 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) with screwdriver. 3. Remove shift catch to the inside with roller (no. 17 and 18 in overview). 4. Pull shift lever outwards with rubber washer (no. 16 and 21 in overview). 5. Lever out shaft seal (no. 19 in overview) with screwdriver.

6. Drive out bearing sleeves (no. 20 in overview) with special tool pressure piece 9648 .

Overview

1871

einordnung

Removing outer bearing race

1. Remove snap ring (no. 2 or 5 in overview) with screwdriver.

2. Drive out 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 pullin tool and extractor P 254 . 3. Remove snap ring (no. 4 or 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 screw plug

1. Unscrew screw plug (no. 1 in overview) with Allen key. top of page

Assembling gear housing

1. Refit gear housing on transmission case and screw in screws. Tightening torque: 23 Nm (17 ftlb.) 2. Assemble front gear set. 3. Fit front transmission case cover.

Removing outer bearing race

1872

einordnung

Assembling gearshift
1. Drive in bearing sleeves (no. 20 in overview) with special tool pressure piece 9648/1 . 2. Drive in shaft seal (no. 19 in overview) with special tool pressure piece 9649/1 . Before doing this, fill the space between the dust and sealing lips with grease (e.g. Liqui Moly). 3. Insert shift lever from outside with rubber washer (no. 16 and 20 in overview). 4. Push shift catch with roller (no. 17 and 18 in overview) onto shift lever from the inside. 5. Push on circlip (no. 15 in overview). 6. Insert locking pin, compression spring and screw plug (no. 14, 13 and 12 in overview) Tightening torque: 20 Nm (15 ftlb.)

Installing outer bearing race

1. Insert snap rings (no. 4 or 7 in overview) into the groove of the outer bearing race. 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 pullin tool and extractor P 254 from the outside. 3. Insert snap rings (no. 2 or 5 in overview).

Installing ball sleeves

1. Drive in ball sleeves (no. 9 and 10 in overview) with special tool pressure piece 9648 . Use short side (installation depth 0.6 mm) of the special tool. 2. Drive in ball sleeves (no. 8 and 11 in overview) with special tool pressure piece 9648 . Use long side (installation depth 1.4 mm) of the special tool.

Installing screw plug

1. Screw in plug screw (no. 1 in overview). Tightening torque: 30 Nm (22 ftlb.) top of page

Tightening torques

Location Gear housing on transmission housing Screw in plug screw (no. 12 in overview) Plug screw (no. 1 in overview)

Thread M8 M M

Tightening torque Nm (ftlb.) 23 (17 ftlb.) 20 (15 ftlb.) 30 (22 ftlb.)

Assembling gearshift

1873

einordnung 996840, 996841

Tightening torques

1874

34 55 37 Disassembling and assembling front transmission cover GT2

Tools Overview Disassembling front transmission case cover Assembling front transmission case cover Tightening torques top of page

Tools

Item Designation of the special Explanation tool A Internal puller 46 56 mm Commercially available Handbuch Werkstattausrstung Kapitel 2.4, Nr. 108 B Counter support Commercially available Handbuch Werkstattausrstung Kapitel 2.4, Nr. 106 C Internal puller 30 40 mm Commercially available Handbuch Werkstattausrstung Kapitel 2.4, Nr. 108 D Counter support Commercially available Handbuch Werkstattausrstung Kapitel 2.4, Nr. 107 E Pressure piece Special tool pressure pieces 9690 F Mandrel Special tool pullin tool and extractor P 254

top of page 34 55 37 Disassembling and assembling front transmission cover GT2 1875

einordnung

Overview

No. 1 2 3 4 5 6 7 8 9 10

Designation Hexagonhead bolt Bearing segment Reverse idler gear Needleroller bearing Pin Snap ring, large Outer bearing race Snap ring, small Cylindricalroller bearing Reversing light switch

Qty. 1 1 1 2 1 1 1 1 1 1 1876

Overview

einordnung 11 Transmission cover 1

top of page

Disassembling front transmission case cover

1. Remove transmission. 34 35 27 Removing and refitting the transmission GT2. 2. Fasten the transmission on assembly support. 3. Drain transmission oil. 34 01 55 Changing transmission oil GT2. 4. Remove 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. Unscrew fastening screws for front transmission case cover and remove transmission case cover.

Disassembling reverse idler gear

1. Unscrew the hexagonhead bolt (no. 1 in overview) 2. Remove toothed segment, reverse idler gear and needleroller bearing.

Dismantling cylinderroller bearing

Note The cylinderroller bearing can be damaged during the dismantling. 1. Disassemble reverse idler gear.

Disassembling front transmission case cover

1877

einordnung

2. Clamp the transmission case cover in the vice. 3. Remove snap ring with pliers 4. Affix internal puller 30 40 mm behind cylindricalroller 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 race

1. Clamp the transmission case cover in the vice. 2. Remove snap ring with pliers

Dismantling cylinderroller bearing

1878

einordnung

3. Affix internal puller 46 56 mm behind outer bearing race. Ensure correct seating. 4. Screw internal puller together with counter support and pull out cylindrical roller bearing by turning the nut on the counter support. top of page

Assembling front transmission case cover

1. Place front transmission case cover onto the transmission and screw in fastening screws. Tightening torque: 23 Nm (17 ftlb.) 2. Fit oil cooler. Tightening torque: 10 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 Removing and refitting the transmission GT2.

Fitting reverse idler gear

1. Insert toothed segment, reverse idler gear and needleroller bearing. 2. Screw in hexagonhead bolt (no. 1 in overview).

Fitting cylindricalroller bearing

Note Always use new cylindricalroller bearing. 1. Drive in cylindricalroller bearing with special tool pressure piece 9690 . 2. Insert snap ring. 3. Fit reverse idler gear.

Disassembling outer bearing race

1879

einordnung

Fitting outer bearing race

1. Drive in outer bearing race with special tool pressure pieces 9690 . 2. Insert snap ring. top of page

Tightening torques

Location Hexagonhead bolt (no. 1 in overview) Transmission case cover fastening screws on transmission housing Oil cooler fastening screws on transmission

Thread M8 M8 M6

Tightening torque Nm (ftlb.) 25 (18.5 ftlb.) 23 (17 ftlb.) 10 (7.5 ftlb.)

996840, 996841

Fitting outer bearing race

1880

34 72 19 Removing and installing transmission oil pump GT2

Tools Removing transmission oil pump Installing transmission oil pump Tightening torques top of page

Tools

Item A

Special tool designation Removal tool

Remarks Shopmade (flat steel 5 x 230)

top of page

Removing transmission oil pump

1. Remove the transmission oil cooler => Removing and installing transmission oil cooler GT2

34 72 19 Removing and installing transmission oil pump GT2

1881

einordnung

2. Unscrew the fastening screws of the oil pump A . 3. Fasten the shopmade removal tool to the oil pump thread B with an M6 x 25 screw and drive the oil pump out of the transmission housing with gentle taps with a hammer on the shopmade removal tool. top of page

Installing transmission oil pump

1. Grease the sealing rings of the transmission oil pump, e.g. with LiquiMoly . 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 transmission housing. Tightening torque: 23 Nm (17 ftlb.) 4. Fit the transmission oil cooler => Removing and installing transmission oil cooler GT2 . top of page

Tightening torques

Location Fastening of transmission oil pump to transmission housing

Thread M 8 x 25 or M 8 x 30

Tightening torque Nm (ftlb.) 23 (17)

996840, 996841

Removing transmission oil pump

1882

34 74 19 Removing and installing transmission oil cooler GT2

Caution Tools Overview Removing transmission oil cooler Installing transmission oil cooler Tightening 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 A

Special tool designation Hose clamp

Remarks Special tool hose clamp VW3093

top of page

Overview

34 74 19 Removing and installing transmission oil cooler GT2

1883

einordnung

A Transmission oil cooler top of page

Removing transmission oil cooler

1. Remove rear, centre and left underbody trim. 2. Drain transmission oil => Changing transmission oil GT2.

3. Unscrew two hexagonhead 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 heating supply and return lines from the plastic clips A and pull the line over the holders of the underbody trim B towards the rear.

Overview

1884

einordnung

6. Seal the coolant line by clamping it with special tool hose clamp VW3093 A .

7. Unscrew the transmission oil connecting line A between the oil cooler and the transmission on the transmission oil cooler. 8. Seal the coolant line by clamping it with special tool hose clamp VW3093 B . 9. Place a suitable container under the vehicle to collect the coolantoil mixture from the transmission oil cooler. WARNING Coolant and transmission oil may emerge during the repair operations described below. With the engine at operating temperature, there is a risk of scalding due to these liquids.

10. Undo the spring band clamp A and pull off the coolant hose.

11. Unscrew the holder screws A and the hexagon socket head bolt B and pull out the transmission oil cooler with the bracket. Removing transmission oil cooler 1885

einordnung Note The cooler bracket can remain hanging on the fastened coolant hose while the transmission oil cooler is replaced. 12. Unscrew the three fastening screws between the transmission oil cooler and the cooler bracket and remove the transmission oil cooler. top of page

Installing transmission oil cooler

1. Fit the oil cooler with new sealing rings on the cooler bracket and screw in the fastening screws. Tightening torque: 10 Nm (7.5 ftlb.) 2. Position the cooler bracket with the transmission oil cooler on the oil pump. 3. Screw in the hexagon socket head bolt between the cooler bracket and the oil pump. Tightening torque: 10 Nm (7.5 ftlb.) 4. Screw in the connecting screws between the holder and the transmission housing. Tightening torque: 23 Nm (17 ftlb.) 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 between the transmission oil cooler and the transmission on the transmission oil cooler. Tightening torque: 34 Nm (25 ftlb.) Note Grease the thread of the transmission oil connecting line, e.g. with Optimol optimoly paste . 8. Push the coolant lines for the heating supply and return lines over the holders of the underbody trim towards the front and clip the lines into the plastic clips. 9. Lay the electrical cable and connect the plug. 10. Fit the transverse strut. Tightening torque: 65 Nm (48 ftlb.) 11. Fill with transmission oil => Changing transmission oil GT2. 12. Fit underbody trims. 13. Bleed the engine cooling system 19 01 07 Bleeding the cooling system . top of page

Tightening torques

Location Installing transmission oil cooler

Thread 1886

einordnung Tightening torque Nm (ftlb.) 10 (7.5) 10 (7.5) 23 (17) 34 (25) 65 (48)

Fastening of oil cooler to cooler bracket Fastening of cooler bracket to oil pump Fastening of oil cooler holder to transmission housing Fastening of transmission oil line to transmission oil cooler Fastening of transverse strut

M 6 x 20 M 6 x 55 M 8 x 20

M 10 x 1.25

996840, 996841

Tightening torques

1887

35 50 19 Removing and installing sealing ring for drive shaft GT2

Tools Removing sealing ring for drive shaft Installing sealing ring for drive shaft Tightening torques top of page

Tools

Item 1 2 3

Special tool designation Pressure piece Assembly sleeve Puller

Remarks Special tool Pressure piece 9256 Special tool Assembly sleeve 9255 Special tool Puller 9629

top of page

Removing sealing ring for drive shaft

1. Remove enginetransmission unit and remove the transmission. => Removing and refitting the transmission GT2 2. Remove guide tube for release bearing.

35 50 19 Removing and installing sealing ring for drive shaft GT2

1888

einordnung

3. Screw special tool puller 9629 securely into the sealing ring. Note The coil spring must be 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 hexagonhead bolt. top of page

Installing sealing ring for drive shaft

Removing sealing ring for drive shaft

1889

einordnung

1. Push special tool assembly sleeve 9255 onto the toothing of the input shaft. 2. Fill the space between the dust and sealing lips on the sealing ring with grease (e.g. LiquiMoly).

3. Drive in sealing ring with special tool pressure piece 9256 as far 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 microencapsulated, therefore replace screws entirely. 5. Clean teeth of the drive shaft and grease with a thin coat of Olista Longtime 3 EP (only as corrosion protection). top of page

Tightening torques

Location

Thread

Tightening torque Nm (ftlb.)

Installing sealing ring for drive shaft

1890

einordnung Guide tube for release bearing on transmission housing M6x14 10

996840, 996841

Tightening torques

1891

39 08 15 Adjusting drive set GT2

Tools Sequence of adjustment operations Determining disc thickness S4 and S5 Determining disc thickness S3 Determining disc thickness S1 and S2 top of page

Tools

Item Designation of the special tool A Measuring mandrel B Centring discs C Universal master gauge D Final dimension plate E Dial gauge F G H I J K Gauge plunger Dial gauge extension (30 mm) Final dimension plate Dial gauge holder Clamping sleeve Adjustment device

Explanation Special tool measuring mandrel VW 385/1 Special tool centring sleeve 9109 Special tool universal master gauge VW 385/30 Special tool final dimension plate VW 385/17 Commercially available Handbuch Werkstattausrstung Kapitel 2.4, Nr. 136 Special tool gauge plunger VW 385/14 Special tool dial gauge extension VW 385/56 Special tool adjusting shim 9281 Special tool dial gauge holder VW 387 Special tool sleeve 9145 Special tool adjustment device VW 521/4

39 08 15 Adjusting drive set GT2

1892

einordnung L M N O P Q R S T Measuring lever Gauge plunger Dial gauge extension (6 mm) Dial gauge extension (20 mm) Clamping device Retaining device Assembly sleeve Micrometer Drift Special tool measuring lever VW 388 Special tool gauge plunger VW 388 Special tool dial gauge extension VW 382/10 Special tool dial gauge extension 9150 Special tool retaining device 9562 Special tool retaining device 9253 Special tool assembly sleeve 9263 Commercially available Handbuch Werkstattausrstung Kapitel 2.4, Nr. 135 Special tool drift P 264 b

top of page

Sequence 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 + S2. 2. Determine disc thickness S4 and S5. 3. Determine disc thickness S3. 4. Divide the total disc thickness into S1 and S2. 5. Check the circumferential backlash and set, if necessary. Note The aim of the adjustment operations is to regain the position of maximum smooth running which was determined in production on a testing machine.

top of page

Determining disc thickness S4 and S5

1. Disassemble the transmission 34 35 37 Disassembling and assembling transmission. Note The input shaft need not be disassembled for this setting.

Tools

1893

einordnung

2. Insert adjusting shim S3 A with a thickness of 1 mm. 3. If the tensioning plate has not been disassembled, install it with the input shaft. Tightening torque: 25 Nm (19 ftlb.)

4. Measure the play at the fourpoint bearing. To do so, fit the dial gauge with the special tool dial gauge holder VW 387 . Press the outer bearing race forwards as far as possible and set the dial gauge to 0. 5. Press the outer bearing race backwards 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: 1.00 mm + 0.05 mm = 1.05 mm = S4 6. Experience shows that the thickness of disc S5 corresponds to the thickness of disc S4. Example: S4 = S5 = 1.05 mm

7. Insert output shaft A with adjusting shim S5 B and adusting shim S4 C into tensioning plate F . 8. Push 4th gear fixed wheel D onto output shaft. The large collar faces the tensioning plate. 9. Push on oil pump drive wheel E . Determining disc thickness S4 and S5 1894

einordnung 10. Insert the preselected adjusting shim S3 into the transmission housing and install the tensioning plates with the shafts. top of page

Determining disc thickness S3

1. Push fixed wheel for 3rd gear on to the output shaft. The narrow collar faces the tensioning plate. 2. 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 nut on to the output shaft. Tightening torque: 300 Nm (222 ftlb.)

6. Set the setting collar on special tool measuring mandrel VW 385/1 to the dimension a ( approx. 65 mm ).

7. Complete the measuring mandrel as shown in the illustration.

Determining disc thickness S3

1895

einordnung

8. Read off the installation dimension E from the crown wheel. 1 Installation dimension E 2 Backlash F 3 Matching number Example: E = 70.20 mm 9. Set the installation dimension E on special tool universal master gauge VW 385/30 and set the dial gauge to 0 with 2 mm pretension. 10. Place special tool adjusting shim 9281 on the pinion head of the output shaft.

11. Insert the measuring mandrel as shown in the illustration. 12. Place the side transmission cover in position without an Oring and pull downwards with 4 screws. Do not knock. Tightening torque: 25 Nm (19 ftlb.) 13. Press tapered roller bearing with the centring 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 the dial gauge is reached. At this point, the dial gauge extension is positioned exactly at right angles to the front face of the pinion head. 15. Read off the deviation from the specified adjusting value E. If the deviation is greater than 0.04 mm, a correction must be carried out. Example: 0.10 mm Note So in the example, the actual value of the adjusting dimension E would not be 70.20 but rather 70.30 mm. 16. In order to achieve the required adjusting dimension E, the adjusting shim S3 must be adjusted by the measured value. Example: new disc thickness S3 = 0.90 mm 17. Determining disc thickness S3 1896

einordnung In order to correct the altered disc S3, disc S4 must be altered in the opposite direction by the determined value. Example: S4 = 1.15 mm (increase by 0.10 mm) 18. As the thickness of disc S4 is identical to the thickness of disc S5, disc S5 must be altered by the same value as disc S4. Example: S5 = S4 = 1.15 mm 19. When the discs S3, S4 and S5 have been corrected appropriately and inserted, the adjusting dimension E should be checked again. top of page

Determining disc thickness S1 and S2

Note The crown wheel must be adjusted again if the transmission housing, the side cover, the tapered roller bearing for the differential, the differential housing or the drive set are replaced.

Determining 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 roller bearing. Note The chamfers of the adjusting shims point towards the housing. 3. Insert the differential into the housing and turn it several times. 4. Mount the side transmission cover without a shaft seal and screw in all screws. Tightening torque: 25 Nm (19 ftlb.) 5. Fit special tool adjustment device VW 521/4 opposite the crown wheel side (S2 side) into the differential.

6. Place the special tool end plate VW 385/17 B on to the differential. 7. Fasten special tool dial gauge holder VW 387 on the housing with the dial gauge and the special tool dial gauge extension VW 385/56 A . 8. Set dial gauge with 2 mm pretension to 0.

Determining disc thickness S1 and S2

1897

einordnung 9. Press the differential upwards as far as possible with special tool adjustment device VW 521/4 . 10. Read off the play on the dial gauge. Example: 0.75 mm Note The differential must not be turned during the measurement, as otherwise the measurement will be falsified. 11. The total thickness of discs S1 and S2 is calculated from the total of the already inserted discs plus the measured value plus the specified bearing pretension of the tapered roller bearing. Example: 5.00 mm + 0.75 mm + 0.40 mm = 6.15 mm = S1 + S2 Note The pretension of the tapered roller bearing in this transmission is always 0.40 mm.

Dividing the total disc thickness into S1 and S2

Note In order to gain as precise a setting of the backlash as possible at this point, the adjusting 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 available in thicknesses from 1.5 to 2.8 mm in increments of 0.05 mm, the calculated result must be rounded off. However, the total of the disc thicknesses S1 + S2 must not be changed. To determine the thickness, measure the adjusting shims at several places with a micrometer. The discs should also be checked for burrs and damage. Example: disc thickness S1 = 2.375 mm; inserted adjusting shim = 2.35 mm Example: disc thickness S2 = 3.775 mm; inserted adjusting shim = 3.80 mm Example: total of both inserted discs = 2.35 + 3.80 = 6.15 1. Remove the differential and pull off both tapered roller bearings. 2. Insert the calculated adjusting shims S1 and S2.

Checking the circumferential backlash and setting, if necessary

Determining total disc thickness S1 + S2

1898

einordnung

1. Read off the backlash at the crown wheel. 1 Installation dimension E 2 Backlash F 3 Matching number 2. Mount the input and output shafts with tensioning plate and adjusting shims. Tightening torque: 25 Nm (19 ftlb.)

3. Mount the gear set and the gear housing. Then assemble front gear 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 with all the screws. Tightening torque: 25 Nm (19 ftlb.) Note Always make sure a certain amount of backlash is present when tightening the screws. The drive pinion must not jam under any circumstances.

Checking the circumferential backlash and setting, if necessary

1899

einordnung 6. Screw in special tool gauge plunger VW 388 with special tool adjustment device VW 521/4 and set the lever length to 91 mm a . 7. Insert special tool adjustment device VW 521/4 into the differential with special tool bushing 9145 and clamp tight. 8. Turn the differential several times in both directions so that the tapered roller bearings can settle. 9. Mount the special tool dial gauge holder VW 387 with the dial gauge in such a way that a right angle is formed between the dial gauge axis and the special tool gauge plunger VW 388 .

10. Install special tool retaining device 9562 . 11. Turn 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 circumferential backlash. 13. This measurement should be performed a further three times. The crown wheel must be turned 90 before every measurement. The difference between the four measurements must not exceed 0.03 mm. Moreover, none of the measurements may deviate by more than 0.04 mm from the circumferential backlash noted on the crown wheel. If any of the specified dimensions is not observed, the adjusting shims S1 and S2 must be replaced again. Note The total disc thickness S1 + S2 must not be changed.

996840, 996841

Checking the circumferential backlash and setting, if necessary

1900

39 22 19 Removing and installing sealing ring for halfshaft flange GT2

Tools Removing sealing ring for halfshaft flange Installing sealing ring for halfshaft flange Tightening torques top of page

Tools

Item

Designation of the special tool Pressure piece

Remarks Special tool Pressure piece 9252

top of page

Removing sealing ring for halfshaft flange

39 22 19 Removing and installing sealing ring for halfshaft flange GT2

1901

einordnung 1. Unclip the Bplus cable from the holder A (only the right side). 2. Uncouple drive shaft on the transmission side. Unscrew the hexagon socket head bolts B .

3. Unscrew the fastening screw between the halfshaft flange and the transmission. 4. Unscrew the halfshaft flange out of the transmission past the drive shaft. 5. Lever out sealing ring using a suitable tool. top of page

Installing sealing ring for halfshaft flange

1. Fill the space between the dust and sealing lips with grease (e.g. LiquiMoly) and drive in the sealing ring up to the mounting face with special tool pressure piece 9252 .

2. Push in the halfshaft flange and tighten the fastening screw. If necessary, hold the halfshaft flange with 2 screws. Tightening torque: 44 Nm (32 ftlbs.). 3. Fitting the halfshaft flange on drive shaft Tightening torque: 81 Nm (61 ftlb.). 4. Clip in the Bplus cable in the holder (only the right side).

Removing sealing ring for halfshaft flange

1902

einordnung top of page

Tightening torques

Location Halfshaft flange fastening screw Halfshaft flange on drive shaft

Thread M10 M10

Tightening torque Nm (ftlb.) 44 81

996840, 996841

Installing sealing ring for halfshaft flange

1903

39 40 19 Removing and installing differential and differential lock GT2.

Tools Overview Removing differential and differential lock Installing diffential and differential lock Tightening torques top of page

Tools

Item A B C D E

Designation of the special tool Pressure piece Pressure piece Pressure piece Mandrel Mandrel

Explanation Special tool Pressure piece 9247/4 Special tool Pressure piece 3062 Special tool Pressure piece 9252 Special toolPullin tool and extractor P254 Special tool mandral VW295

top of page

Overview

39 40 19 Removing and installing differential and differential lock GT2.

1904

einordnung

No. 1 2 3 4 5 6 7 8 9 10

Designation Hexagonhead bolt Halfshaft flange Hexagonhead bolt Cover for final drive Oring Differential lock Shaft seal Bearing outer race Bearing outer race Transmission housing

Qty. 2 2 12 1 1 1 2 1 1 1

top of page

Overview

1905

einordnung

Removing differential and differential lock

1. Remove transmission. 34 35 27 Removing and refitting the transmission GT2. 2. Fasten the transmission on assembly support. 3. Pull out hexagonhead bolts (no. 1 in overview) and halfshaft flange (no. 2 in overview). 4. Unscrew hexagonhead bolts (no. 3 in overview) and disassemble cover for final drive (no. 4 in overview), possibly with a rubber hammer. 5. Remove differential. top of page

Installing diffential and differential lock

1. Insert differential. 2. Insert cover with new, lightly oiled Oring (no. 5 in overview) and screw in hexagon head bolts. Tightening torque: 25 Nm (18.5 ftlb.) 3. Push in halfshaft flange and screw in hexagonhead bolts. Tightening torque: 44 Nm (32,5 ftlb.) 4. Refitting transmission. 34 35 27 Removing and refitting the transmission GT2. top of page

Tightening torques

Location Halfshaft flange fastening screws Cover fastening screws

Thread M8 M6

Tightening torque Nm (ftlb.) 44 (32,5 ftlb.) 25 (18.5 ftlb.)

996840, 996841

Removing differential and differential lock

1906

39 40 37 Assembling and disassembling differential and differential lock GT2

Tools Overview Disassembling GKN differential lock Assembling GKN differential lock Tightening torques top of page

Tools

Item A B C D

Designation of the special tool Connecting piece Pressure piece Pressure piece Clamping jaws

Explanation Shopmade (flat steel 6 x 18) Special tool pressure piece P263 Special tool pressure piece P264b Special tool clamping jaws 9646

top of page

Overview

39 40 37 Assembling and disassembling differential and differential lock GT2

1907

einordnung

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Designation Large inner race of tapered roller bearing Adjusting shim Small inner race of tapered roller bearing Adjusting shim Hexagonhead bolt Crown wheel Countersunk screw Lids Thrust plate Cup spring Outer discs Inner disc Thrust ring (outside)

Qty. 1 X 1 X 12 1 3 1 2 2 4 4 1 1908

Overview

einordnung 14 15 16 17 18 Shaft bevel gear (with threaded washer) Bevel pinion Axle Thrust ring (inside) Housing 2 4 2 1 1

top of page

Disassembling GKN differential lock

1. Remove differential. 39 40 19 Removing and installing differential and differential lock. GT2

2. Clamp differential lock in the vice with special tool clamping jaws 9646 . 3. Remove tapered roller bearing A with puller. 4. Undo hexagonhead bolts B and remove the crown wheel C .

5. Unscrew 3 crossrecess screws A and remove lid B . Note The installation position of the lid in relation to the housing is marked for refitting. 6. Remove inner parts see overview . top of page

Assembling GKN differential lock

Note

Disassembling GKN differential lock

1909

einordnung The complete disc pack should always be replaced in the case of repairs. Replacing individual discs is not permissible. Oil discs, thrust rings and axles lightly with transmission oil before fitting. 1. Insert inner parts see overview . If necessary, affix thrust plates with viscous grease. 2. Put on cover and screw in cross recess screws. Tightening torque: 15 Nm (11 ftlb.) 3. Insert crown wheel and screw in hexagonhead bolts. Tightening torque: 200 Nm (148 ftlb.) Note The hexagonhead bolts must always be replaced. 4. Press tapered roller bearing on with special tool drift P 264 b. Note Depending on the type of repairs / replaced parts, 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 and driving the other. To do this, clamp one flange in the vice with two screws and position differential. Insert second drive flange with shopmade connecting piece A and turn differential with a torque measuring tool. A basic locking torque from 5 to 15 Nm (4 to 11 ftlb.) must be achieved. 6. Install differential. 39 40 19 Removing and installing differential and differential lock GT2. top of page

Tightening torques

Location Crossrecess screw for cover on housing Hexagonhead bolts for crown wheel fastening

Thread M6 M12

Tightening torque Nm (ftlb.) 15 (11 ftlb.) 200 (148 ftlb.)

Assembling GKN differential lock

1910

einordnung 996840, 996841

Tightening torques

1911

46 16 24 Installing air ducts for PCCB brake discs GT2

Note Installing front air ducts Installing rear air ducts Note The air ducts (brakeair spoiler) on the front suspension of GT2 vehicles with PCCB brakes are larger than those of a conventional brake system! Exclusively for PCCB brakes, air ducts (brakeair spoiler) are also mounted on the rear suspension! These air ducts are not mounted during transport! CAUTION Damaged, worn or missing aerodynamic components such as spoilers or underside panels affect the driving behaviour 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 ducts

1. Mount the air duct (brakeair spoiler) on the front control arm (clip in similar to the standard air spoiler on the Carrera 996 and Turbo 996). Then insert the expansion rivet (included in the scope of delivery) into the bore present arrow . In vehicles with the model year 01, the bore arrow must also be drilled in the wheel housing behind (8 mm, drill through from the existing bore). 2. Mount the air duct in the same manner on the other side of the vehicle. top of page

46 16 24 Installing air ducts for PCCB brake discs GT2

1912

einordnung

Installing rear air ducts

1. Push air duct (brakeair spoiler) onto the lower rear axle control arm from the front.

Subsequently fit the retaining clip 2 (included in the scope of delivery) from the rear. The retaining clip 2 must be inserted into the slot of the air duct arrow at the top. Connect 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 and one from behind). Note The illustration shows the rear of the air duct 1 (removed)! The left and right air duct 1 and retaining clip 2 differ from eachother! 2. Mount the air duct in the same manner on the other side of the vehicle.

996840, 996841

Installing rear air ducts

1913

46 36 20 Removing and installing the front disc brake pads GT2 / Turbo with PCCB
Caution Removal Installation WARNING Danger of accident if brake pads with the wrong brake pad quality are installed! Use only the typespecific brake pads in the Porsche Spare Parts Catalogue! Note The GT2 is equipped with PCCB (Porsche Ceramic Composite Brake) as standard! In 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 fitted on each of the brakepad supports!

Vibration dampers are provided as additional damping measures! Replace vibration dampers each time the pads are changed! The damper plates have an adhesive protective film! The protective film must be pulled off before installation!

46 36 20 Removing and installing the front disc brake pads GT2 / Turbo with PCCB

1914

einordnung

When fitting the vibration dampers on the small pistons, the cutout on the vibration damper arrow is to be positioned at the brake pads guide pins as otherwise the vibration damper will be deformed!

top of page

Removal
CAUTION PCCB (Porsche Ceramic Composite Brake): Danger of material damage during wheel removal/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) are located in the luggage compartment!

1. Screw the 2 assembly aids (assembly pins), instead of 2 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.

Removal

1915

einordnung

2. Undo the screw on the retaining pin. Counter the retaining pin when doing this.

3. Pull out the retaining pin towards the inside. 4. Pull out the warning contact wire on the brake caliper and remove the warning contacts from the brake pad plates. Note Replace warning contacts if the core of the wire is worn or worn through! The warning contact can continue to be 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 the container)! 5. Set back the brake pads as far as possible with the piston resetting fixture (press back)!

6. Pull out brake pads together with the damper plates (remove). If this is not possible (depending on wear of the brake pads), use a spatula to detach the damper plates from the brake pad backing plate before removing the pads. top of page

Removal

1916

einordnung

Installation
WARNING Danger of accident if old parts are fitted on brake caliper! Fit new expanding spring and new retaining pin with a new screw on the brake caliper! Note Ensure correct brake pad quality! Use brake pads as per Spare Parts Catalogue! The pad backing plates (rear side of the brake pads) must not be greased!

For a wheel installation, 2 assembly aids (assembly pins) must be screwed into the wheel hub! 1. Before 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 fixture. 3. Fit new damper plates in the pistons. As the vibration dampers are provided with a protective film, the protective film must be removed before installation.

4. When fitting the vibration dampers on the small pistons, the cutout on the vibration damper arrow is to be positioned at the brake pads guide pins as otherwise the vibration damper will be deformed! 5. Insert the brake pads.

Installation

1917

einordnung

6. Fit new expanding spring and new retaining pin with a new screw on the brake caliper! These parts are available as a repair set and must be renewed each time the pads are changed. When tightening the screw, counter at the retaining pin! Tightening torque of the screw = 25 3 Nm (2 ftlb.) 7. Insert the warning contact wire and warning contacts. 8. Firmly press the brake pedal several times to position the brake pads on the brake discs. 9. Check and, if necessary, correct the brake fluid level.

Bedding in the brake pads

New brake pads require a slightly longer beddingin period for PCCB brake discs than cast iron brake discs. In general, the following applies: New brake pads must be broken in (beddingin period), their optimum braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking effect must be compensated for by increased pressure on the brake pedal. The same also applies after a brake disc change.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Bedding in the brake pads

1918

46 38 20 Removing and installing the rear disc brake pads GT2 / Turbo with PCCB
Caution Removal Installation WARNING Danger of accident if brake pads with the wrong brake pad quality are installed! Use only the typespecific brake pads in the Porsche Spare Parts Catalogue! Note The GT2 is equipped with PCCB (Porsche Ceramic Composite Brake) as standard! In 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 fitted on each of the brakepad supports!

Vibration dampers are provided as additional damping measures! Replace vibration dampers each time the pads are changed! The damper plates have an adhesive protective film! The protective film must be pulled off before installation!

46 38 20 Removing and installing the rear disc brake pads GT2 / Turbo with PCCB

1919

einordnung

top of page

Removal
CAUTION PCCB (Porsche Ceramic Composite Brake): Danger of material damage during wheel removal/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) are located in the luggage compartment!

1. Screw the 2 assembly aids (assembly pins), instead of 2 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 the retainer (safety bracket) arrow and extract the retainer pin inwards. 3. Pull out the warning contact wire on the brake caliper and remove the warning contacts from the brake pad plates. Note Replace warning contacts if the core of the wire is worn or worn through! The warning contact can continue to be used if there are only scrape marks on the plastic part of the warning contact!

Removal

1920

einordnung If necessary, remove some brake fluid by suction from the brake fluid reservoir (brake fluid may escape over the rim of the container)! 4. Set back the brake pads as far as possible with the piston resetting fixture (press back)! 5. Pull out brake pads together with the damper plates (remove). If this is not possible (depending on wear of the brake pads), use a spatula to detach the damper plates 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 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 backing plates (rear side of the brake pads) must not be greased!

For a wheel installation, 2 assembly aids (assembly pins) must be screwed into the wheel hub! 1. Before installation of the brake pads, check the wear of the brake discs => Checking rear PCCB brake discs (wear assessment) . 2. If necessary, press back the piston to its original position using the resetting fixture. 3. Fit new damper plates in the pistons. Remove protective film from the damper plates before installation. 4. Insert the brake pads.

Installation

1921

einordnung

5. Fit new expanding spring, new retaining pin and new retainer (safety bracket) arrow ! These parts are available as a repair set and must be renewed each time the pads are changed! 6. Insert the warning contact wire and warning contacts. 7. Firmly press the brake pedal several 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 slightly longer beddingin period for PCCB brake discs than cast iron brake discs. In general, the following applies: New brake pads must be worn in (beddingin period), their optimum braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking effect must be compensated for by increased pressure on the brake pedal. The same also applies after a brake disc change.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Bedding in the brake pads

1922

46 50 19 Removing and installing the front PCCB brake disc

Removal Explanation of 2part brake disc Installation top of page

Removal
CAUTION PCCB (Porsche Ceramic Composite Brake): Danger of material damage during wheel removal/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) are located in the luggage compartment!

1. Screw the 2 assembly aids (assembly pins), instead of 2 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. Subsequently (after the wheel is disassembled) remove the 2 assembly aids (assembly pins) again. Note In order to gain better access for assembly work, it is beneficial to turn the wheels fully either to the right or the left! 3. Press the electrical lead for the speed sensor/wear indicator out of the holder. 4. Undo the plug coupling for the speed sensor/wear indicator on the wheel carrier. 5. Loosen holder for brake line at wheel carrier. 6. Disengage the electrical lead for the wear indicator from the clips. 7. Set the brake pads back slightly with the piston resetting fixture . 8. 46 50 19 Removing and installing the front PCCB brake disc 1923

einordnung Undo the brake caliper on the wheel carrier and hang it in a suitable place in the wheel well (do not open the brake hydraulics!). 9. Take off the brake disc after removing the countersunk screws. top of page

Explanation of 2part brake disc

The PCCB brake discs consist of two parts on the front and rear axles. The brake disc 1 is screwed to the brakedisc chamber 2 with 10 screws (M6) 3 . The complete brake disc only is available as a spare part (disc + brakedisc chamber)! Do not separate the brakedisc chamber 2 and brake disc 1 from each other. It is also not permissible and not necessary to turn the screws 3 . The screws are safeguarded against turning by 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 2 Brakedisc chamber 3 Screw (10 ea.) top of page

Installation
Note Do not confuse right and left brake discs during assembly! Distinguishing characteristic: Involute shape, identification and spare part number (SP No.)! The front PCCB brake discs of the Turbo and GT2 are different. Use the correct brake disc when replacing! The front PCCB brake discs are marked with GT or Turbo, R = right or L = left and with an arrow for the direction of rotation (additional diffence to right or left)! Spare part on lefthand side third group number is odd. Example: SP No. Left brake disc = 996.351.031.92. Spare part on righthand side third group number is even. Example: SP No. Right brake disc= 996.351.032.92. Removal 1924

einordnung 1. Check that all parts are in perfect condition and replace them if necessary. 2. Clean the levelling and centring surfaces on the brake disc and wheel hub. 3. Apply a very thin coat of Optimoly TA to the centering surface on the wheel hub. 4. Fit the brake disc. Note Replace the brake caliper fastening screws after each removal! The brake caliper fastening screws of the GT2 and Turbo with PCCB are 8 mm longer (85 mm) than on the 911 Turbo with cast iron brake discs (77 mm)! 5. Fit brake caliper with new fastening screws. Tightening 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 brake pads require a slightly longer beddingin period for PCCB brake discs than cast iron brake discs. In general, the following applies: New brake pads must be worn in (beddingin period), their optimum braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking effect must be compensated for by increased pressure on the brake pedal. The same also applies after a brake disc change.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

1925

46 53 19 Removing and installing the rear PCCB brake disc

Removal Explanation of 2part brake disc Installation top of page

Removal
CAUTION PCCB (Porsche Ceramic Composite Brake): Danger of material damage during wheel removal/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) are located in the luggage compartment!

1. Screw the 2 assembly aids (assembly pins), instead of 2 wheel bolts, into the wheel hub before wheel removal/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 assembly aids (assembly pins) again.

3. With a screwdriver, turn the adjustment device towards "release" through a wheel bolt threaded hole. 4. Set the brake pads back slightly with the piston resetting fixture . 5. Open the plug connection on the wheel carrier and pull out the plug for the brake pad wear indicator. 6. Remove the brake caliper from the wheel carrier and suspend it in the wheel arch (do not open brake hydraulics). First, pull out the electrical wires on the brake caliper holder and the brake pad wear wire on 46 53 19 Removing and installing the rear PCCB brake disc 1926

einordnung the wheel carrier holder. 7. Take off the brake disc after removing the countersunk screws. If a stuck brake disc cannot be removed, evenly screw hexagonhead bolts into the two M8 threads of the brake disc, thereby pressing off the disc. top of page

Explanation of 2part brake disc

The PCCB brake discs consist of two parts on the front and rear axles (illustration shows front brake disc). The brake disc 1 is screwed to the brakedisc chamber 2 with 10 screws (M6) 3 . The complete brake disc only is available as a spare part (disc + brakedisc chamber)! Do not separate the brakedisc chamber 2 and brake disc 1 from each other. It is also not permissible and not necessary to turn the screws 3 . The screws are safeguarded against turning by the 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 2 Brakedisc chamber 3 Screw (10 ea.) top of page

Installation
Note Do not confuse right and left brake discs during assembly! Distinguishing characteristic: Involute shape, identification and spare part number (SP No.)! The brake discs are marked with R = right or L = left and with an arrow for the direction of rotation (additional difference of right or left)! Spare part on lefthand side third group number is odd. Example: SP No. Left brake disc = 996.352.031.02. Spare part on righthand side third group number is even. Example: SP No. Right brake disc= 996.352.032.02. 1. Check that all parts are in perfect condition and replace them if necessary. 2. Clean the levelling and centring surfaces on the brake disc and wheel hub. Removal 1927

einordnung 3. Apply a very thin coat of Optimoly TA to the centering surface on the wheel hub. 4. Fit the brake disc. 5. Adjust the parking brake shoes and parking brake cables. Note Replace the brake caliper fastening screws after each removal! The brake caliper fastening screws for PCCB brake discs are 8 mm longer (85 mm) than on cast iron brake discs (77 mm)! 6. Fit brake caliper with new fastening screws. Tightening torque of the fastening screws = 85 Nm (63 ftlb.).

7. 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 brake pads require a slightly longer beddingin period for PCCB brake discs than cast iron brake discs. In general, the following applies: New brake pads must be worn in (beddingin period), their optimum braking effect is therefore not reached until after a few hundred kilometers. The slightly reduced braking effect must be compensated for by increased pressure on the brake pedal. The same also applies after a brake disc change.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation

1928

47 01 07 Bleeding brake GT2

General Bleeding brakes top of page

General
The 911 GT2 is equipped with 3channel ABS (ABS 5.3) without PSM (Porsche Stability Management) and without TC (Traction Control). Note Observe brakefluid quality! Use only new DOT4 brake fluid! The brakefluid change interval using Super DOT4 brake fluid is two years! This brake fluid is available under the following part numbers: Quantity supplied 1 litre = 000.043.203.66! Container quantity 30 litres = 000.043.203.67!

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Bleeding brakes
CAUTION For vehicles with extremely high mileage or for very old vehicles, damage to the brake master cylinder can occur and the primary boots can be damaged! Double the number of pumping cycles and use only half of the master brake cylinder stroke! 1. Fill reservoir to its top edge with new brake fluid.

2. Connect a bleeding device to the brake fluid reservoir. Switch on the bleeding device. Bleeding pressure approximately 2.0 bar. Note Bleed the outer bleeder valve first!

47 01 07 Bleeding brake GT2

1929

einordnung 3. Continue bleeding at the brake calipers in the sequence: Sequence: Rear right / rear left / front left / front right. 4. Open each bleeder valve until clear, bubblefree brake fluid emerges. 5. Use a transparent hose and a collecting bottle to check the escaping brake fluid accurately for cleanliness, lack of air bubbles and to determine the brake fluid used. After installing a new brake master cylinder and/or a new hydraulic 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 procedure in the sequence rear left / front right / front left. This will remove all air bubbles (from the primary circuit). Note Also carry out this procedure if the brake hydraulics was largely empty or if after bleeding residual air can be detected by excessive brakepedal travel!

6. Switch off and disconnect the bleeding device. Correct the brake fluid level if necessary.

996840, 996841

Bleeding brakes

1930

34 35 37 Disassembling transmission GT2

Tools Removing transmission cover Disassembling front gear set Removing gear housing Removing input and output shaft Disassembling output shaft Dismantling input shaft top of page

Tools

Item Designation of the special tool A Striker B Socket wrench insert C Retaining device D Threaded piece E Pressure pieces F Twoarmed extractor, span 250 G Separator 17 75 cm H J

Explanation

Special tool Striker VW 771 Special tool Socket wrench insert 9105 Special tool Retaining device 9253 Special tool Threaded piece VW 771/15 Special tool Pressure pieces 9656 Commercially available Handbuch Werkstattausrstung Kapitel 2.4, Nr. 103 Commercially available Handbuch Werkstattausrstung Kapitel 2.4, Nr. 109 Twoarmed extractor, span Commercially available Handbuch Werkstattausrstung Kapitel 120 2.4, Nr. 101 Socket wrench insert Special tool Socket wrench insert 9282 1931

34 35 37 Disassembling transmission GT2

einordnung K Puller hook, 400 mm long Commercially available Handbuch Werkstattausrstung Kapitel 2.4, Nr. 105

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Removing transmission cover

1. Remove transmission. 34 35 27 Removing and refitting the transmission 2. Fasten the transmission on assembly support. 3. Drain transmission oil. 34 01 55 Change transmission oil. 4. Remove 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. Screw in special tool threaded piece vw 771/15 in thread A . Drive oil pump up and out with special tool striker vw 771 . 8. Unscrew fastening screws for front transmission case cover and force transmission case cover off with a rubber hammer if necessary. top of page

Disassembling front gear set

Overview

Tools

1932

einordnung

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Designation Hexagon nut (selflocking) Cylindricalroller bearing Thrust plate Loose gearwheel, reverse gear Synchronising ring Needleroller bearing Bearing inner race Shift collar Washer Hexagonhead bolt Shift fork (reverse gear) Spring Ball

Qty. 1 1 1 1 1 1 1 1 2 2 1 3 3 1933

Overview

einordnung 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 Driver dog Guide sleeve with snap ring Loose gearwheel, 5th gear Synchronising ring Needleroller bearing Bearing inner race Shift collar Driver dog Ball Spring Guide sleeve Shift fork (5th and 6th gears) Synchronising ring Loose gearwheel, 6th gear Needleroller bearing Bearing inner race Thrust plate Hexagon nut (selflocking) Bearing inner race Fixed gearwheel, reverse gear Spacer sleeve Fixed gear wheel, 5th gear Spacer sleeve Fixed gearwheel, 6th gear Housing 3 1 1 1 1 1 1 3 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Disassembling gear set

1. Remove transmission cover. 2. Fix the transmission with special tool retaining device 9253 and shift into a gear.

3. Remove nut A on input and output shaft. 4. Unscrew clamping screw from shift forks B . 5. Disassembling gear set 1934

einordnung Remove fixed gearwheel for reverse gear (no. 33 in overview) from the input shaft using the puller and special tool pressure pieces 9656 . When doing so, pull off bearing inner race (no. 32 in overview). 6. Remove spacer sleeve (no. 34 in overview) from the input shaft. 7. Remove loose gearwheel for reverse gear (no. 4 in overview) with needleroller bearing (no. 6 in overview) from the output shaft using the puller and special tool pressure pieces 9656 . When doing so, also pull off the cylindricalroller bearing (no. 2 in overview) and thrust plates (no. 3 in overview). 8. Push complete gear set forwards onto output shaft using two mounting levers 1 2 cm. 9. Push gear set back behind the bearing inner race (no. 7 in overview) and remove bearing inner race using the puller and special tool pressure pieces 9656 . 10. Open up shift fork and remove 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 needleroller bearing (no. 18 in overview). 13. Remove bearing inner race using puller and special tool pressure pieces 9656 . 14. Open up shift fork and remove complete synchonization. 15. Remove loose gearwheel, 6th gear (no. 27 in overview) with needleroller bearing (no. 28 in overview). 16. Remove bearing inner race (no. 29 in overview) using puller and special tool pressure pieces 9656 . 17. Remove thrust plate (no. 30 in overview). top of page

Removing gear housing

1. Remove transmission cover. 2. Disassembling front gear set.

3. Unscrew screw A and remove oil tube B . 4. Unscrew fastening screws between gear housing and transmission and remove studs. 5. Unscrew plug screw C and remove the spring with locking pins. 6. If necessary force gear housing off with a rubber hammer. top of page

Removing input and output shaft

Removing gear housing

1935

einordnung

Overview

No. 1 2 3 4 5 6 7 8 9 10

Designation Cylindricalroller bearing Thrust plate Loose gear wheel, 1st gear Friction ring Tapered ring Synchronising ring Needleroller bearing Bearing inner race Shift collar Guide sleeve

Qty. 1 1 1 1 1 1 1 1 1 1 1936

Overview

einordnung 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Driver dog Ball Spring Synchronising ring Tapered ring Friction ring Loose gear wheel, 2nd gear Needleroller bearing Bearing inner race Thrust plate 3rd gear fixed gear wheel Oil tube Locking element Shift rod (1st/2nd gear) Intermediate locking element Shift rod (reverse gear) Selector shaft Shift rod (5th/6th gear) Tensioning plate Hexagon nut Shift rod (3rd/4th gear) Cylindricalroller bearing Screw plug Spring Ball Adjusting shim S3 Transmission housing Oil pump drive wheel Fixed gearwheel, 4th gear 3 3 3 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 7 1 1 4 4 4 X 1 1 1

Removing shafts
1. Unscrew screw plugs (no. 33 in overview) of the locking elements and remove springs (no. 34 in overview) and ball (no. 35 in overview). 2. Pull out reverse gear shift rod (no. 26 in overview) and shift rods for 5th/6th gear (no. 28 in overview) towards the front. Pay attention to the intermediate lock (no. 25 in overview) and locking elements (no. 23 in overview) during this procedure. 3. Remove differential lock. 39 40 19 Removing and installing differential and differential lock GT2. 4. Remove oil tube (no. 22 in overview). 5. Removing shafts 1937

einordnung Remove cylindricalroller bearing (no. 32 in overview) from input shaft using a puller. 6. Pull loose gearwheel for 1st gear (no. 3 in overview) off the input shaft with the thrust plate (no. 2 in overview) and cylindricalroller bearing (no. 1 in overview). 7. Pull off the fixed wheel for 3rd gear (no. 21 in overview) with synchronisation 1st/2nd gear (no. 16 to 4 in overview) and loose gearwheel for 2nd gear (no. 17 in overview). Note A specific 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 overview) with shafts and remaining gear wheels. 9. Remove drive wheel of the oil pump (no. 38 in overview) and fixed wheel for 4th gear (no. 39 in overview) and take output shaft out of the tensioning plate. top of page

Disassembling output shaft

Overview

No. 1 2 3 4 5

Designation Adjusting shim S4 Adjusting shim S5 Bearing inner race 53.5 Fourpoint bearing Bearing ring 56.0 mm

Qty. X X 1 1 1 1938

Disassembling output shaft

einordnung 6 7 Cylindricalroller bearing Output shaft 1 1

Disassembling shaft
1. Remove adjusting shim (no. 1 and 2 in overview) from shaft. Note the quantity and thickness for reinstallation.

2. Press cylindricalroller bearing (no. 6 in overview) off with bearing inner race (no. 5 and 3 in overview) and fourpoint bearing (no. 4 in overview). top of page

Dismantling input shaft

Overview

Overview

1939

einordnung

No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Designation Hexagon nut (selflocking) Cylindricalroller bearing Bearing inner race Fourpoint bearing Tensioning plate Bearing inner race Shift rod / 3rd/4th gear shift fork Locking element Thrust plate Loose gear wheel, 4th gear Synchronising ring Needleroller bearing Bearing inner race

Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1940

Overview

einordnung 14 15 16 17 18 19 20 21 22 Guide sleeve Shift collar Driver dog Ball Spring Synchronising ring Loose gear wheel, 3rd gear Needleroller bearing Input shaft 1 1 3 3 3 1 1 1 1

Disassembling 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 synchronisation (no. 11 to 19 in overview), loose gearwheel for 4th gear (no. 10 in overview) and the remaining parts (in overview 2 to 9).

996840, 996841

Disassembling shaft

1941

34 35 37 Assembling transmission GT2

Tools Assembling input shaft Assembling input shaft Installing input and output shaft Fitting gear housing Assembling front gear set Fitting front transmission case cover top of page

Tools

Item A B C

Designation of the special tool Retaining device Socket wrench insert Socket wrench insert

Explanation Special tool Retaining device 9253 Special tool Socket wrench insert 9282 Special tool Socket wrench insert 9105

top of page

Assembling input shaft

34 35 37 Assembling transmission GT2

1942

einordnung

Assembling shafts
Note The overview diagram of the input shaft is provided in the chapter disassembling transmission under Disassembling input shaft . 1. Clamp shaft with special tool socket wrench insert 9282 in the vice.

2. Assemble synchronization if necessary. The synchronization consists of parts 19 to 14 and 11 in the overview. Pay attention to correct seating of the steel synchronising rings A and the driver dogs B . The driver dogs with spring and ball must align with the dotting marks on the shift collar. Make sure furthermore that the rectangular indentations of the synchronising rings are positioned above the driver dogs.

3. Check the synchronising rings for wear. check synchronising rings by pushin them onto the gear 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 needleroller bearing (no. 21 in overview), 3rd gear loose gearwheel (no. 20 in overview) and synchronisation onto input shaft. 5. Heat bearing inner race (no. 13 in overview) to 120C and push onto input shaft. 6. Push 4th gear loose gearwheel (no. 12 and 10 in overview) and thrust plate (no. 9 in overview) onto input shaft. 7. Heat bearing inner race (no. 6 in overview) to 120C and push onto input shaft. 8. Fit clamping plate with short lock (no. 5 and 8 in overview), fourpoint bearing (no. 4 in overview) and shift fork (no. 7 in overview) onto input shaft. 9. Heat bearing inner race (no. 3 in overview) to 120C and push onto input shaft. 10. Heat cylindricalroller bearing (no. 2 in overview) to 120C and push onto input shaft. 11. Screw new hexagon nut onto input shaft. Tightening torque: 250 Nm (185 ftlb.) Assembling shafts 1943

einordnung

Tightening torques

Location Hexagon nut (no. 1 in overview)

Thread M30 x 1.5

Tightening torque Nm (ftlb.) 250

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Assembling input shaft

Assembling shaft
Note The overview diagram of the output shaft is provided in the chapter disassembling transmission under Disassembling output shaft . 1. Heat cylindricalroller bearing (no. 6 in overview) to 120C and push onto output shaft. 2. Heat bearing inner race (no. 5 in overview) to 120C and push onto output shaft. 3. Push on fourpoint bearing (no. 4 in overview) onto output shaft. 4. Heat bearing inner race (no. 3 in overview) to 120C and push onto output shaft. top of page

Installing input and output shaft

Installing shafts
Note An overview diagram of the installation is provided in the chapter 'disassembling transmission' under Removing input and output shaft .

Tightening torques

1944

einordnung

1. Insert output shaft A with adjusting shim S5 B and adusting shim S4 C into tensioning plate F . 2. Push 4th gear fixed wheel D onto output shaft. The large collar faces the tensioning plate. 3. Push on oil pump drive wheel E .

4. Affix adusting shim S3 A in the transmission case with viscous grease. 5. Insert input and output shaft into the transmission case with tensioning plate and tighten nuts. Tightening torque: 25 Nm (18.5 ftlb.) 6. Push on 3rd gear fixed gear (no. 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 120C and push onto output shaft. 9. Push needleroller bearing (no. 18 in overview) onto bearing inner race.

10. Check synchronisation of 1st/2nd gear. To do this, place the friction ring, the tapered ring and the synchronising ring on the gear wheel. Measure the gap A with a feeler gauge. Perform test for 1st and 2nd gear. Installation dimension (new): 1.5 to 2.0 mm Wear dimension: 1.2 mm 11. Push 2nd gear loose gearwheel (no. 17 in overview) onto needleroller bearing. Installing shafts 1945

einordnung 12. Insert friction ring (no. 16 in overview), tapered ring (no. 15 in overview) and synchronisation ring (no. 14 in overview) into the guide sleeve (no. 10 in overview) and push onto output drive. In doing so, the recess of the inner toothing of the guide sleeve must align with the oil bore of the output shaft. 13. Heat bearing inner race (no. 8 in overview) to 120C and push onto output shaft.

14. Fit shift collar (no. 9 in overview) with shift rod for 1st/2nd gear (no. 24 in overview). The turned groove A in the shift collar must face the 2nd gear loose wheel. Note The dotting marks on the shift collar must be centred with 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 Shift collar 2 Ball 3 Driver dog 4 Spring A Recognition groove B Dotting mark C 2ndgear side E 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. 17. Fit the synchronising ring (no. 6 in overview), the tapered ring (no. 5 in overview) and friction ring (no. 4 in overview). 18. Push needleroller bearing (no. 7 in overview) onto bearing inner race. 19. Push 1st gear loose gearwheel (no. 3 in overview) and thrust plate (no. 2 in overview) onto output shaft. Installing shafts 1946

einordnung 20. Heat cylindricalroller bearing (no. 1 in overview) to 120C and push onto output shaft. 21. Heat cylindricalroller bearing (no. 32 in overview) to 120C and push onto input shaft. 22. Fit oil tube (no. 22 in overview). Use new microencapsulated screw. Tightening torque: 6 Nm (4.5 ftlb.)

23. Fit shift rods, selector shaft and locking elements. Affix locking elements with viscous grease if necessary. Ensure that that the rollers on the selector shaft are complete. 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 Shift rod for 1st/2nd gear 24. Fit locking elements (no. 33, 34 and 35 in overview). Note Do not move the shift rods past the neutral lock or gear lock during or after fitting as otherwise the small locking elements and the balls of the lock can fall into the transmission.

Tightening torques

Location Tensioning plate on transmission case Oil pipe on tensioning plate

Thread M8 M5

Tightening torque Nm (ftlb.) 25 6

Tightening torques

1947

einordnung top of page

Fitting gear housing

Fitting housing
1. Coat gear housing with Loctite 574 and put it on. To do this, insert shift rods into suitable bearing locations and ensure correct engaging of the shift catch roller in the driver of the selector shaft. 2. Screw in fastening screws. Tightening torque: 23 Nm (17 ftlb.) 3. Fit locking pin, spring and plug screw. Tightening torque: 15 Nm (11 ftlb.)

Tightening torques

Location Gear housing fastening screws Plug screw

Thread M8 M 10 x 1

Tightening torque Nm (ftlb.) 23 15

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Assembling front gear set

Note The overview diagram of the front gear set is provided in the chapter 'disassembling transmission' under Disassembling front gear set .

Assembling gear set

1. Place thrust plate (no. 30 in overview) onto output shaft. 2. Heat bearing inner race (no. 29 in overview) to 120C and place on output shaft. 3. Place fixed gear for 6th gear (no. 37 in overview) onto the input shaft. 4. Place spacer sleeve (no. 36 in overview) onto input shaft.

Fitting gear housing

1948

einordnung

5. Check the synchronising rings for wear. To do this, push the synchronising rings onto the gear wheels and measure the gap A with a feeler gauge. Installation dimension (new): min. 0.9 mm Wear dimension: 0.6.....0.7 mm 6. Place loose gearwheel for 6th gear (no. 27 in overview) with needleroller bearing (no. 28 in overview) onto output shaft.

7. Assemble synchronisation (no. 26, 24 to 20 and 17 in overview). The rectangular recesses of the synchonisation ring must be positioned above the driver dogs in the case of the steel synchronisation ring (no. 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. Heat bearing inner race (no. 19 in overview) to 120C and place on output shaft. 10. Place loose gearwheel for 5th gear (no. 16 in overview) with needleroller bearing (no. 18 in overview) onto output shaft. 11. Place fixed gear for 5th gear (no. 35 in overview) onto the input shaft. 12. Place spacer sleeve (no. 34 in overview) onto input shaft. 13. Assemble synchronisation (no. 15, 12 to 8 and in overview). Note The dotting marks on the shift collar must be centred with respect to the recesses in the guide sleeve.

Assembling gear set

1949

einordnung

14. Check the synchronising ring for wear. To do this, press synchronising ring onto the gear wheels and measure the gap A with a feeler gauge. Installation dimension (new): min. 0.9 mm Wear dimension: 0.6.....0.7 mm 15. Place synchronisation with shift fork (no. 8 in overview) onto output shaft. 16. Heat bearing inner race (no. 7 in overview) to 120C and place on output shaft. 17. Place loose gearwheel for reverse gear (no. 4 in overview) with needleroller bearing (no. 6 in overview) and synchronisation ring (no. 5 in overview) onto output shaft. 18. Place fixed gearwheel for reverse gear (no. 33 in overview) onto input shaft. 19. Heat bearing inner race (no. 32 in overview) to 120C and place on input shaft. 20. Tighten new selflocking 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 cylindricalroller bearing (no. 2 in overview) to 120C and place on output shaft. 23. Tighten new selflocking nuts (no. 1 in overview) on output shaft. Tightening torque: 300 Nm (222 ftlb.) 24. Adjust shift forks (no. 25 and 11 in overview). The shift collar must have slight play in both directions in idle position. 25. Secure shift forks with screws and washers (no. 9 and 10 in overview). Tightening torque: 18 Nm (13 ftlb.) 26. Remove special tool (retaining device) 9253 . 27. Shift through all gears as a test.

Tightening torques

Location Nuts on output shaft Nuts on input shaft Shift fork screws

Thread M 30 x 1.25 M 22 x 1.5 M8

Tightening torque Nm (ftlb.) 300 200 18

top of page Tightening torques 1950

einordnung

Fitting front transmission case cover

Fitting cover
1. Coat front transmission case cover with Loctite 574, put on and screw in fastening screws. Tightening torque: 23 Nm (17 ftlb.) 2. Fit the oil pump. To do this, drive in oil pump with a rubber hammer and screw in screws. Tightening torque: 23 Nm (17 ftlb.) 3. Fit oil cooler. To do this, screw in hexagon socket head bolt A and two hexagonhead boltsB . Tightening torque for hexagon socket head bolt: 10 Nm (7.5 ftlb.) Tightening torque for hexagonhead 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 transmission oil. 7. Remove transmission from assembly support and fit onto the engine. 34 35 27 Removing and refitting the transmission

Tightening torques

Location Fastening screws of front transmission case cover Oil pump fastening screws Hexagon socket head bolt of oil cooler Hexagonhead bolt of oil cooler

Thread M8 M8 M6 M8

Tightening torque Nm (ftlb.) 23 23 10 23

996840, 996841

Fitting front transmission case cover

1951

45 46 19 Removing and installing front ABS lead (GT2)

Removing front ABS lead Installing front ABS lead Tightening torques Tools

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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 panel cover at centre and left. 6, 664419 Removing and installing cowl panel cover 45 46 19 Removing and installing front ABS lead (GT2) 1952

einordnung

1. Release lead lock for the ABS plug connection arrow A and pull off both plugs arrow B . 2. Undo fastening screw 1 .

3. Take the lead out of the holders arrows A . 4. Open the clips arrows 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 lead in area E and remove it.

7. Cut through the fabric tape in the radiator tank, in the area a , and expose the remaining ABS lead. top of page

Removing front ABS lead

1953

einordnung

Installing front ABS lead

1. Position socket in installation position and secure using fastening screw 1 . => Tightening torques 2. Insert both plugs arrow A . 3. Fold back lead lock arrow B until it can be felt to engage on the plugs.

4. Press 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 C and close the clips arrows D . 7. Push the lead through to the interior arrow E .

Note

Choose the connection point at a position with sufficient room for connecting all the individual leads.

Installing front ABS lead

1954

einordnung Do not cut the ends of the lead too short so that the connection area can be moved from the original installation position, if necessary, if there is insufficient space available. 8. Cut the ends of the lead in the radiator tank to the required length and crimp in area a with a crimp connector and crimping tool. => Tools Cut off leads to different lengths (due to the shrink connection). Slide shrinkfit hose over the leads. Strip 10 mm of insulation off the leads. Connect leads with crimp connectors (do not confuse colours of the individual leads). Shrink shrinkfit hoses with a hotair 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 tiewraps c . Install cowl panel cover at centre and left. 6, 664419 Removing and installing cowl panel cover Install front wheel housing liner. 6, 505619 Removing and installing front wheel housing liner Fit front wheel. => Removing and installing the wheel Turbo and GT2

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Tightening torques

Location Fastening screw 1 for securing ABS lead to spring strut

Thread Tightening torque [Nm] (ftlb.) M6 9.7 (7.2)

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Tools

Item 1

Designation of special tool Repair set for wiring harness 1551

Remarks Workshop Equipment Manual, Gr. 2.4

996840, 996841

Tightening torques

1955

50 30 19 Removing and installing air guide

Removing and installing air guide

GT2

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Removing and installing air guide

50 30 19 Removing and installing air guide

GT2

1956

einordnung

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

Removing and installing air guide

1957

55 90 19 Removing and installing rear lid GT2

Removing and installing rear lid

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Removing and installing rear lid

55 90 19 Removing and installing rear lid GT2

1958

einordnung

No. Designation 1 Electrical plug connection Cable retainer

Qty. Removal 1 Press the lug arrow A of the electrical plug connection 1 and separate. Press and open the lugs of the cable retainer 2 . Remove electrical wire. Unscrew fastening screws.

Installation Connect electrical plug connection 1 .

3 4

Fastening screws Rear lid

4 1

Insert the electrical wire into the cable retainer 2 and close the cable retainer. Ensure that the lugs have engaged correctly. Tightening torque: 10 Nm (7.5 ftlb.) Adjust lid 3 to the hinges in accordance with the contours of the wings and the rear spoiler => Diagram body gap dimensions

Removing and installing rear lid

1959

einordnung 996840, 996841

Removing and installing rear lid

1960

55 90 37 Disassembling and assembling rear lid GT2

Disassembling rear lid Assembling rear lid

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Disassembling rear lid

55 90 37 Disassembling and assembling rear lid

GT2

1961

einordnung

No. Procedure Removing rear spoiler 1 Remove additional brake light 3 2 Remove rubber cover 4 3 Remove adjusting element 4 Remove upper part of lock 8 5 Remove fan with fan housing 10

Instructions 665819 Removing and installing rear spoiler GT2 Disengage cover A at the sides, unlock lock B . Remove brake light and disconnect plug connection C . Pull rubber cover 4 out of the rear lid. Unscrew rubber pad 5 and disengage collar 6 . Unscrew fastening screws 7 and remove upper part of lock 8 . Disconnect plug connections for fan and engine compartment lighting on the fan housing. Unscrew fastening screws 9 and remove fan with fan housing 10 .

Disassembling rear lid

1962

einordnung

No. Procedure 6 Remove mount 12 7 Remove air guide 14 8 Remove air guide 16 9 Remove bracket 19

Instructions Unscrew fastening screws 11 from the mount 12 . Unscrew fastening screws 13 and remove air guide 14 . Unscrew fastening screw 15 from the air guide 16 . Unscrew the fastening nuts 18 and the washers 17 from the bracket 19 .

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Disassembling rear lid

1963

einordnung

Assembling rear lid

No. Procedure 1 Install bracket 19

Instructions Position the bracket 19 on the rear lid and screw in the fastening screws 18 and the lock washer 17 loosely. Position the brackets 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 necessary, shift the bracket. 2. Tilt the rear spoiler und and down several times. Make sure that the rear spoiler fork 20 is guided into the bracket 19 free of tension.

Assembling rear lid

1964

einordnung 3. Remove the rear spoiler. 4. Tighten the fastening screws 18 and the lock ring 17 . Tightening torque: 10 Nm (7.5 ftlb.) Install air guide Insert air guide 16 and screw into place with the fastening screw 15 . 16 Tightening torque: 10 Nm (7.5 ftlb.) Install air guide Screw the air guide 13 into place on the inside of the lid with the fastening 13 screws 14 . Make sure that the seal 14A is fitted all around the air guide 13 . Tightening torque: 10 Nm (7.5 ftlb.) Install mount Position mount 12 . Tighten the fastening screws 11 . 12 Tightening torque: 10 Nm (7.5 ftlb.)

2 3

No. Procedure 5 Assembling rear lid

Instructions

1965

einordnung Install fan with Position the fan housing and fan 10 on the mount. Tighten with the fastening fan housing 10 screws 9 . Connect plug connections for fan and engine compartment lighting on the fan housing. Install upper part Position upper part of lock 7 and fasten with fastening screws 8 . of lock 8 Install adjusting Engage collar 6 . Screw in rubber pads 5 . Apply plasticine to the rubber element pad, close and open the lid. Determine the thickness of the plasticine and screw the rubber pad in or out accordingly. => Diagram body gap dimensions Install rubber Press the rubber cover 4 into the rear lid 1 . cover 4 Install additional Push on electrical plug C . Insert the brake light into the rear lid. Lock the brake light 3 lock B . Engage cover A . Installing rear 665819 Removing and installing rear spoiler GT2 spoiler

6 7

8 9

Replace model logo

1. Position logo with the dimensions X = 360 mm and Y = 20 mm on the rear lid and affix.

Removing and installing rearlid wiring harness

Replace model logo

1966

einordnung

No. 1

Designation Electrical plug connection

Qty. 1

Additional brake light

Wiring harness 1

Removal Press the lug of the electrical plug connection arrow and separate. Cut through the tie wrap on the gasfilled shock absorber (for the engine compartment lid) using side cutters. Disengage the cover at the side, unlock lock in direction of arrow . Remove brake light and disconnect the plug connection. A Pull out grommet with brake light lead. Disconnect plug connection B for fan on fan housing. C engine compartment

Installation Plug in the electrical plug connection. Fasten the lead on the shock absorber for the engine compartment lid with a tie wrap. Connect the plug and insert the brake light. Lock the lock in opposite direction of arrow . Clip in cover. Lay the wiring harness and fasten lead into the mount with the fastening clips. Connect the plug C for the engine 1967

Removing and installing rearlid wiring harness

einordnung lighting, remove plug. Arrow compartment lighting and B press fastening clips together and pull for the engine compartment fan. out of the mount. Push the plug A with the grommet through the opening in the rear lid until the grommet can be pushed into place.

996840, 996841

Removing and installing rearlid wiring harness

1968

63 15 19 Removing and installing front spoiler

Removing front spoiler Installing front spoiler

GT2

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Removing front spoiler

63 15 19 Removing and installing front spoiler

GT2

1969

einordnung

No.

1 2

3 4

Turn hexagon cap nut 2 by 45 and remove. Undo sheetmetal screws 4 from the front part 1 . Remove direction Press in spring clip of direction indicator light arrow A at the indicator light. sides with a screwdriver and take out the direction indicator light 5 , disconnect electrical plug connection. Undo front spoiler at the On the front spoiler, undo the fastening screws 6 and spacer sides. sleeve 7 from the retaining strips on the left and right. Undo front spoiler on the Undo fastening screws 8 of the front spoiler on the underbody. underbody. Remove front spoiler 1 to the front.

Procedure Remove wheel housing liner Remove cover.

Instructions 505619 Removing and installing wheel housing liner

top of page Removing front spoiler 1970

einordnung

Installing front spoiler

No. Procedure 1 Fit front spoiler 1 .

2 3 4

Fit front spoiler on the underbody. Fit front spoiler at the sides. Fit cover.

Instructions Lift the front spoiler 1 near the headlights above the radiators on the right and left. Note: When inserting over the radiators, make sure that the covers are not pressed out of the front spoiler! Position front spoiler on the underbody and screw in place with the fastening screws 10 . Affix front spoiler to the retaining strip and fasten it with the sheetmetal screw 6 and spacer sleeve 7 . Fasten the front end 1 with the sheetmetal screws 4 . Affix cover 3 , turn hexagon cap nuts 2 by 45.

Installing front spoiler

1971

einordnung 5 Fit direction indicator light. Install wheel housing liner Connect electrical plug connection of the direction indicator light 5 . Insert lug arrow of the direction indicator light into the front end 1 and clip into the sheetmetal clip. 505619 Removing and installing wheel housing liner

996840, 996841, 996430, 996431

Installing front spoiler

1972

63 15 37 Disassembling and assembling front spoiler GT2

Disassembling front spoiler Installing front spoiler

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Disassembling front spoiler

63 15 37 Disassembling and assembling front spoiler

GT2

1973

einordnung

No. 1

Procedure Remove covering cap 2

2 3 4

Instructions Carefully press out covering cap 2 with a screwdriver. Cut through the securing cord3 which links the front end 1 and the covering cap. Remove covering frame Press in the lugs of the covering frame 4 and lift it up and off 4 carefully. Remove air outlet frame Unscrew fastening screws 5 from the air outlet frame 6 . 6 Remove frame centre Carefully press the spring nut 8 out of the pegs of the front end 9 1 on the top side using a screwdriver. The spring nuts 8 are destroyed during removal. Guide the frame centre 9 out of the pegs of the front end towards the rear. Remove grille frame Carefully disengage the spring nuts 8 from the pegs of the front 10 left, right end all the way round using a screwdriver. Guide the grille frame 1974

Disassembling front spoiler

einordnung 10 out of the pegs towards the rear out of the front end 1 .

Removing front spoiler

No. Procedure 1 Undo fastening screws 3 2 Remove front spoiler 1

Instructions Undo fastening screws 4 from the front spoiler 1 and the wheel housing liner 2 at the sides. Press in the lugs with a screwdriver, at the same time pull off the front spoiler 1 outwards.

top of page Removing front spoiler 1975

einordnung

Installing front spoiler

No. Procedure 1 Install grille frame 10 2 Install frame centre 9 3 Install air outlet frame 6 4 5

Install covering frame 4 Install covering cap Pull the securing cord 3 through the eyelet in the covering cap 2 and

Instructions Position the grille frame 10 on all sides in the pegs of the front end 1 . Press the spring nut 8 on to the pegs of the front end 1 . Position the grille frame 9 in the pegs of the front end 1 . Press the spring nut 8 on to the pegs of the front end 1 . Check and, if necessary, replace sheetmetal nuts 7 . Position air outlet frame 6 on the front end 1 . Secure the air outlet frame 6 with the fastening screws 5 . Lock covering frame 4 into the front end 1 .

Installing front spoiler

1976

einordnung 2 . the front end 1 .

Installing front spoiler

No. Procedure 1 Fit front spoiler 1 2 Tighten front spoiler 1

Instructions Insert the front spoiler 1 into the groove of the front end. Make sure that all lugs are engaged. Place the sheetmetal nut 5 in position on the front end. Use the fastening screws 4 and spacer sleeves 3 to tighten the front spoiler at the sides with the wheel housing liner 2 to the front end 1 .

Installing front spoiler

1977

einordnung 996840, 996841

Installing front spoiler

1978

66 58 19 Removing and installing rear spoiler

Removing rear spoiler Installing rear spoiler

GT2

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Removing rear spoiler

66 58 19 Removing and installing rear spoiler

GT2

1979

einordnung

CAUTION Damage to paintwork when the rear spoiler is removed with the rear lid closed! Only remove the rear spoiler with the rear lid open.

No. 1 2 3

Instructions Unscrew fastening screw 1 . Guide covering frame 2 out. 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 open. Remove the rear spoiler 5 from Swivel the rear spoiler 5 upwards arrow A and the rear lid guide it out in the direction of the arrow arrow B .

Procedure Remove covering frame 2

Removing rear spoiler

1980

einordnung

top of page

Installing rear spoiler

CAUTION Change in handling, the balance from the front to the rear axle is affected! The additional wing is set to the 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. 6 for use on racing tracks. The additional wing must be moved to the lowest position for use in public traffic.

Installing rear spoiler

1981

einordnung No. Procedure Unscrew the fastening screws 3 fully Open the rear lid 1 Fit the rear spoiler 5 on to the rear lid Instructions To simplify the installation of the rear spoiler, the fastening screw 3 and the clamping piece 4 should be unscrewed fully. Only install the rear spoiler with the rear lid open. 1. Place the rear spoiler 5 on to the rear lid. Ensure that the pegs A of the rear spoiler fork are guided into the bracket 7 . 2. Tilt the rear spoiler und and down several times. Make sure that the rear spoiler fork 6 is guided into the bracket 7 free of tension. If necessary, shift the bracket 7 55 Disassembling and assembling rear lid 3. Tighten the fastening screws 3 and the clamping piece 4 .

Tightening torque: 23 (17) Fit fastening screws Position the clamping piece 4 and tighten the clamping piece with the 3 fastening screw 3 . Tightening torque: 10 Nm (7.5 ftlb.) Install covering Guide covering frame 2 in. Screw in fastening screw 1 . frame 2

Replacing rear spoiler fork

1. Removing and installing rear spoiler fork a. Unscrew the fastening screws 1 from the rear spoiler fork 2 and the rear spoiler 3 . b. Replace rear spoiler fork Note During installation, the fastening screws 1 must always be secured with Loctite 240 inset . c. Position the rear spoiler fork 2 on the rear spoiler 3 . Secure the rear spoiler fork 2 with the fastening screws 1 . Tightening torque: 10 Nm (7.5 ftlb.)

Replacing rear spoiler fork

1982

einordnung 996840, 996841

Replacing rear spoiler fork

1983

69 72 19 Removing and installing rollover bar GT2

Removing rollover bar Installing the rollover bar Adjusting the rollover bar Assembly instructions for the rear trim, the floor covering and the closure caps

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Removing rollover bar

69 72 19 Removing and installing rollover bar GT2

1984

einordnung

Before the removal of the base cage C , the bucket seats must be removed! 707219 Removing and installing bucket seats => Assembly instructions for the rear trim, the floor covering and the closure caps No. 1 Procedure Move right and left sections (Apillar support) A, B to each other to relieve the tension and disconnect the front transverse connection Instructions 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 (Apillar support) A, B by screwing in above the adjusting element 2 in the direction of the arrow Y into the left section (Apillar support) B . Unscrew the fastening screws 3 from the retainer plate 4 and the right section (Apillar support) A . Unscrew the fastening screws 3 from the right section (Apillar support) A and the base cage C . 1985

Detach right section (Apillar support) A

Removing rollover bar

einordnung 3 Detach right section A on the underbody Unscrew the fastening nuts 5 and the washer 6 from the right section (Apillar support) A . Guide the section (Apillar support) A out of the passenger compartment to the right. Detach left section B on the Unscrew fastening nuts 5 and washer 6 from the underbody left section (Apillar support) B . Detach left section (Apillar support) Unscrew the fastening screws 3 from the left B section (Apillar support) B and from the base cage C . Guide the section (Apillar) B out of the passenger compartment to the left.

4 5

No. Procedure 6 Remove selector sleeves 9

Instructions Unscrew fastening nuts 5 from the fastening screws 8 . 1986

Removing rollover bar

einordnung Push the selector sleeves 9 on to the spring dome support sections C, D . Remove base cage C on right side Unscrew the fastening nuts 5 and the washer 6 from of underbody the base cage C . Remove base cage C on left side of Unscrew the fastening nuts 5 and the washer 6 from underbody the base cage C . Guide the base cage C out of the passenger compartment.

7 8

Note In order to unscrew the fastening nuts 7 from the spring strut mount, the vehicle must be standing on its wheels.

No. Procedure Instructions 9 Detach right spring Unscrew the fastening nuts 7 and guide the spring dome support section dome support D out of the right spring strut mount. section D 1) Carry out a test drive after performing assembly work on the rollover bar/spring strut mount threaded parts on the body and then retighten the fastening nuts (three per side) to the torque: 46 Nm (34 ftlb.). The fastening nut 7 must always be replaced. 10 Detach left spring Unscrew the fastening nuts 7 and guide the spring dome support section dome support E out of the left spring strut mount. section E 1) Carry out a test drive after performing assembly work on the rollover bar/spring strut mount threaded parts on the body and then retighten the fastening nuts (three per side) to the torque: 46 Nm (34 ftlb.). The fastening nut 7 must always be replaced.
1) Only

when commissioning the vehicle without a rollover bar

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Installing the rollover bar

Installing the rollover bar

1987

einordnung

DANGER Retighten with correct tightening torque! Carry out a test drive after performing assembly work on the rollover bar/spring strut mount threaded parts on the body and then retighten 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 base cage C . Only then tighten the threaded parts with the prescribed tightening torques. Adjust the adjusting element 2 last.

Installing the rollover bar

1988

einordnung No. 1 Procedure Instructions Install right spring dome Position the spring dome support section D in the rear of the support section D passenger compartment onto the spring strut mount on the right. Tighten in place with the fastening nuts 7 . The fastening nut 7 must always be replaced. Tightening torque: 46 Nm (34 ftlb.) Carry out a test drive after performing assembly work on the rollover bar/spring strut mount threaded parts on the body and then retighten the fastening nuts (three per side) to the torque: 46 Nm (34 ftlb.). Install left spring dome Position the spring dome support section E in the rear of the support section E passenger compartment onto the spring strut mount on the left. Tighten in place with the fastening nuts 7 . The fastening nut 7 must always be replaced. Tightening torque: 46 Nm (34 ftlb.) Carry out a test drive after performing assembly work on the rollover bar/spring strut mount threaded parts on the body and then retighten the fastening nuts (three per side) to the torque: 46 Nm (34 ftlb.). Install base cage on right Position the base cage C on the fastening plate. Install the of vehicle floor washers 6 and the fastening nuts 5 . Tightening torque: 23 Nm (17 ftlb.) Install base cage C on Position the base cage C on the fastening plate. Install the left of vehicle floor washers 6 and the fastening nuts 5 . Tightening torque: 23 Nm (17 ftlb.) Install the base cage C Push selector sleeves 9 onto the spring dome support sections and selector sleeves 9 on the left and right D, E . Position the base cage C onto the sections of the spring dome support A, B . Push the selector sleeves upwards over the connector tube of the base cage. Screw the hole pattern of the selector sleeves on the hole pattern of the base cage C and of the spring dome support sections D, E . Install the fastening screws 8 and tighten with the fastening nuts 5 . Tightening torque: 16 Nm (12 ftlb.)

Installing the rollover bar

1989

einordnung

No. Procedure Instructions 6 Install right section (Apillar Guide the right section (Apillar support) A inwards from the support) A right door. Position on the fastening plate on the vehicle floor and screw into place with the washers 6 and the fastening screws 5 . Tightening torque: 23 Nm (17 ftlb.) 7 Install right section A on Screw into place on the screwed points of the base cage C with the base cage C the fastening screws 3 . Tightening torque: 23 Nm (17 ftlb.) 8 Install left section (Apillar Guide the left section (Apillar support) B inwards from the left support) B door. Position on the fastening plate on the vehicle floor and screw into place with the washers 6 and the fastening screws 5 . Tightening torque: 23 Nm (17 ftlb.) 9 Install left section B on the Screw into place on the screwed points of the base cage C with base cage C the fastening screws 3 . Installing the rollover bar 1990

einordnung Tightening torque: 23 Nm (17 ftlb.) 10 Install the transverse Press the adjusting element 2 screwed into the transverse connection of the sections connection into the groove Z of the section (Apillar support) (Apillar support) A, B at A . At the same time, install the retainer plate 4 and screw the front into place with the fastening screws 3 . Tightening torque: 23 Nm (17 ftlb.) => Adjusting the rollover bar

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Adjusting the rollover bar

The foam coating of the Apillar 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 the foam coating 3 of the Apillar support sections on the left and right A, B are pressed against the cowl panel frame trim. 2. Screw the lock nut 1 in the direction of the arrow X as far as it will go against the adjusting element 2 and lock it against the adjusting element 2 . top of page

Assembly instructions for the rear trim, the floor covering and the closure caps

Adjusting the rollover bar

1991

einordnung

No. 1

Designation Rear cover 1

Qty. 1

Removal Lift the rear cover 1 up and out.

Installation Press the rear cover 1 in between the sidepanel lining and the rollover bar D, E .2) In vehicles where the rollover bar has been removed, the rear cover may be replaced if necessary (for reasons of appearance).1) Press in the flaps in the floor covering 2 around the rollover bar A, B, C . After the rollover bar has been removed, the flaps in the floor covering should be closed with the closure caps 3 .1)

Flaps in the floor covering 2 Closure caps 3

Pull out the flaps in the floor covering 2 . In order to install the rollover bar, the closure caps 3 should be removed from the floor covering, inset 2 2)

1) Only 2) Only

after removal of the rollover bar during installation of the rollover bar

996840, 996841

Assembly instructions for the rear trim, the floor covering andthe closure caps

1992

72 01 19 Removing and installing bucket seat as of MY 2001

Removing bucket seat GT2 Installing bucket seat GT2

GT2

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Removing bucket seat GT2

72 01 19 Removing and installing bucket seat

GT2 as of MY 2001

1993

einordnung

No. Procedure 1 Remove seat rail cover

2 3

Undoing seat screws at front Undoing seat screws at rear

Instructions Insert a screwdriver under the locking tabs and press lightly upwards. Caution! Locking tabs can break. Pull front seat rail cover 2 out of the right and left seat rails towards the 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. Move seat to its front limit position and undo the M10 x 28 Torx screws 3 from the right and left seat rails using an E12 socket wrench insert.

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Removing bucket seat GT2

1994

einordnung

Installing bucket seat GT2

No. 1

Procedure Fitting seat screws at rear Fitting seat screws at front Fit seat rail cover 2 Fit sixpoint seat belt

3 4

Instructions Position seat rails on the seat baseframe, screw the rear M10 x 28 Torx screws 3 into the seat baseframe on the left and right using the E12 wrench socket and tighten with tightening torque: 65 Nm (48 ftlb.). 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 with tightening torque: 65 Nm (48 ftlb.). Push seat rail cover 2 into front end of the left and right seat rails until the locking tab audibly engages. => Fitting sixpoint seat belt &ndash; GT2

Installing bucket seat GT2

1995

einordnung

Fitting sixpoint seat belt

GT2

1. Loop technique for fastening the seat belt to the bucket seat cross member Loop the belt strap in the direction of the arrow inset around the bucket seat transverse strut into the adjustible slider. The projection dimension = X of the belt strap must be at least 100 mm.

2. Pulling sixpoint seat belt through the openings in the bucket seat Pull sixpoint 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 belt fitting 5 at the left and right on the seat frame. With the shim 3 and the fastening screw 2 , screw the belt fitting 5 tight. Position the cover 1 on the fastening screw 2 . Use the foam part 4 for the Club Sport version. For the Cup racing version, mount the bushing 6 instead of the foam part. Tightening torque: 50 Nm (37 ftlb.) Fitting sixpoint seat belt GT2 1996

einordnung

4. Loop technique for fastening the seat belt to the bucket seat cross member a. Loop the belt strap in 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 belt strap and bind it with a tie wrap 1 .

996840, 996841

Fitting sixpoint seat belt

GT2

1997

96 61 19 Removing and installing relay for main switch GT2 as of MY 2001

Installing the main battery relay Installing inner EMERGENCY STOP switch Removing the main battery relay Removing the 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 EMERGENCY STOP switch in the front left cowl panel cover of the fluid tank and the necessary wiring are prefitted.

96 61 19 Removing and installing relay for main switch GT2 as of MY 2001

1998

einordnung CAUTION The vehicle must not be driven on public roads when in the Racing track status! When the inner or outer EMERGENCY STOP switch is actuated, the entire electrical system is disconnected from the battery. This means that all electrical consumers are switched off, including those required for driving on public roads. The handling behaviour of the vehicle is changed due to the deactivated power supply for the control electronics. top of page

Installing the main battery relay

Note After the installation of the main battery relay and switching off using the inner/outer EMERGENCY STOP switch, the Work instructions after disconnecting the battery described in Chapter 9 must be observed 91 General . The battery may discharge if kept at a standstill 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 maximum 60 Ah). Fasten using the hexagonhead bolt M 8 x 16 enclosed in the delivery scope (tightening torque 23 Nm (17 ftlb.)). 1. Remove the battery cover, the available ground cable from the battery to the bulkhead and the right cowl panel cover 702219 Removing and installing cowl panel cover .

2. In the case of a lefthand drive vehicle, lay the ground cable 1 prefitted on the main battery relay from the relay (terminal 88) along behind the battery and connect it (tightening torque 6 Nm (4.5 ftlb.)). 3. In the case of a righthand drive vehicle, replace the ground cable prefitted on the main battery relay with the enclosed (shorter) cable and connect it to the ground terminal of the battery (tightening torque 6 Installing the main battery relay 1999

einordnung Nm (4.5 ftlb.)). 4. Lay the ground cable from the relay (terminal 88a) to the right body/bulkhead ground point and screw it in place (tightening torque 20 Nm (15 ftlb.)). 5. Lay the positive cable 2 from the main battery relay (prefitted) to the positive battery terminal and screw it in place on the positive terminal with the hexagonhead bolt M 6 x 12 (tightening torque 6 Nm (4.5 ftlb.).

6. The additional plug connection 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 6pin additional plug connection from the jumper plug and the wiring harness.

7. Engage the plug connection in the 6pin support on the main battery relay. top of page

Installing inner EMERGENCY STOP switch

Note The necessary EMERGENCY STOP switch is delivered depending on the additional equipment present:

EMERGENCY STOP switch in the centre console M 581.

Installing inner EMERGENCY STOP switch

2000

einordnung

EMERGENCY STOP switch without centre console M 581 in front of shift lever. 1. Carefully unclip the standard cover trims upwards with a suitable tool (e.g. screwdriver; plastic spatula).

2. The 3pin plug connection required for the EMERGENCY STOP switch is located under the cover in front of the shift lever and is marked with a white identification tape A . Connect the 3pin plug to the plug connection of the EMERGENCY STOP switch and clip the 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 instructions after disconnecting the battery 91 General described in Chapter 9 must be observed. 1. Remove the battery cover and the right cowl panel cover 702219 Removing and installing cowl panel cover. 2. Disconnect the ground terminal of the battery and lower away frfom the battery terminal.

3. Disconnect the 6pin plug connection on the main battery relay by pressing on the locking lever and Removing the main battery relay 2001

einordnung pulling the plug connection apart.

4. Lay the 6pin plug under the right cowl panel cover and connect the plug to the 6pin plug located under the right dome strut. Fasten the plug connection to the wiring harness with a tie wrap. 5. Unscrew the hexagonhead bolt M 6 x 12 on the positive cable 2 at the positive battery terminal.

6. Remove the ground cable 1 from the relay (terminal 88) (in lefthand drive vehicles laid next to the battery). In righthand drive vehicles, make sure that the battery is installed in the opposite manner from that shown in the illustration. 7. Unscrew the ground 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 hexagonhead bolt M 8 x 16 designed for fastening the main battery relay holder and remove the main battery relay including holder, wiring and hexagonhead bolt from the vehicle. 10. Connect the battery ground cable to the ground terminal of the battery and tighten the hexagonhead bolt with a tightening torque of 6 Nm (4.5 ftlb.). 11. Fit the cowl panel cover and the battery cover. top of page

Removing the inner EMERGENCY STOP switch

The necessary EMERGENCY STOP switch is installed depending on the additional equipment present:

Removing the inner EMERGENCY STOP switch

2002

einordnung

EMERGENCY STOP switch in the centre console M 581.

EMERGENCY STOP switch without centre console M 581 in front of shift lever. 1. Carefully unclip the cover trims with the EMERGENCY STOP switch upwards with a suitable tool (e.g. screwdriver; plastic spatula).

2. Disconnect the 3pin 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 identification tape A into the shaft in the centre console. Clip the standard cover without EMERGENCY STOP switch into place. top of page

Operating the main battery switch

Status A Road . Status B Racing track

Operating the main battery switch

2003

einordnung

Note Turn the red actuation toggle (on the main battery relay) clockwise as far as the stop, status A (bayonet). The main battery relay and the inner and outer EMERGENCY STOP switches are without function.

Note

Turn the red actuation toggle anticlockwise and remove, status B .

Outer EMERGENCY STOP switch left cowl panel 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 compartment lid.

Actuating inner EMERGENCY STOP switch

Push lever of the toggle switch forwards. Fold the transparent cover of the emergency switch forwards and press the red switch. The switch position Racing track is displayed with a warning lamp in the switch.

Status A Road . Status B Racing track

2004

einordnung

Moving the EMERGENCY STOP switch to its starting position

Press the red emergency switch once more and close the cover. Note After the installation of the main battery relay and switching off using the inner/outer EMERGENCY STOP switch, the Work instructions after disconnecting the battery 91 General described in Chapter 9 must be observed.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Moving the EMERGENCY STOP switch to its starting position

2005

53 05 55 Replacing rear 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 panel Carrera 4S

2006

einordnung

WARNING During body repairs, the following safety instructions and the general information and quality instructions must be followed. => Safety instructions for raising vehicles => Safety instructions for welding => Safety instructions for sticking => Safety instructions for installation work => Safety instructions for corrosion protection => General information and quality notes Note The accessories in the repair area should be removed, depending on the extent of the damage.

Cutting out rear closing panel

2007

einordnung All straightening work on the body in this area must have been completed before the damaged parts are removed.

No. Procedure Placing vehicle on the alignment bench 1 Separating the spotwelded joint at the rear closing panel. 2 Separating the spotwelded joint at the rear closing panel. 3 Separating the spotwelded joint on the engine mount at top 4 Separating the spotwelded joint on the engine mount at bottom

Instructions Place the vehicle with the units mounted at the front onto the set of straightening attachments and fasten it in position. Use a spotweld cutter to separate the connection between the inner side members and the rear closing panel A on the left and right. Use the spotweld cutter to separate the connection between the side section on the inside and the rear closing panel B, C . Separate the spotwelded joint between the engine mount at top D and the inner side member and the connection to the inner side section F with the spotweld cutter. Use the spotweld cutter to separate the spotwelded joint between the engine mount at bottom E and the inner side member.

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Inserting rear closing panel

Inserting rear closing panel

2008

einordnung

No. Procedure Instructions 1 Cleaning welding areas and Remove underbody coating and paint layers, etc. from the welding preparing spare parts areas of the body with a hotair gun or rotary brush.Remove the factoryapplied primer on the welding areas of the spare parts using the rotary brush. Drill or punch (with a hole punch) 7 mm holes spaced 20mm apart for plugwelding with shielding gas. 2 Inserting the closing panel Insert the closing panel spare part into the body and fasten it to the into the body straightening attachments. If necessary, align it with the inner side sections and the side members. Fit the lid and set the gap dimensions => Gap dimensions, body rear => Removing and installing rear lid Carrera 4S Fit lower lock part of the rear lid and check whether the upper lock part engages in the lower lock part. Inserting rear closing panel 2009

einordnung 3 Plugwelding the engine mount/side member at top under shielding gas Spotwelding the closing panel/side members on the inside Plugweld the engine mounts at the left and right to the side member at top D under shielding gas. Plugweld the connection F to the inner side section with an approx.10 mm full weld. Plugweld the connection between the inner side members A and the closing panel under shielding gas.

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Tools and materials

Item 1 Tools Remarks Basic straightening Gr. 3; attachments for 911 Carrera Workshop (996) Equipment Manual Additional straightening Gr. 3; attachments for 996 Workshop Equipment Manual Star gauges no. 1271 Gr. 2.4; Workshop Equipment Manual MIG welder Gr. 3; Workshop Equipment Manual Multispot spotwelder Gr. 3; Workshop Equipment Manual Pneumatic body saw Gr. 3; Workshop Equipment Manual Angle grinder Gr. 3; Workshop Equipment Manual Oscillating body saw Gr. 3; (special electrical cutter) Workshop Equipment Manual Multispot spotweld cutter Gr. 3; Workshop Equipment 2010

Tools and materials

einordnung Manual Gr. 2.4; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 3; Workshop Equipment Manual Gr. 2.4; Workshop Equipment Manual

10

Hole punch

11

Hotair gun

12

Rotary brush

13

Spotweld cutter 7 mm no. 129

996430, 996431, 996630, 996631

Tools and materials

2011

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

einordnung

No. 1 2 3 4

Designation Wheel housing liner Sheetmetal screw Plastic nut T5 Sheetmetal nut

Qty. 1 7 5 2

Removal Pull out downwards. Unscrew. Unscrew.

Installation

Inspect and replace if necessary. Inspect and replace if necessary. Removing and installing frame with heat shield, see: 635019 Additional assembly instructions for installation of the bumper Carrera 4S

996430, 996431

53 69 19 Removing and installing rear wheel housing liners Carrera 4S

2013

55 90 19 Removing and installing rear lid Carrera 4S

55 90 19 Removing and installing rear lid Carrera 4S

2014

einordnung

No. 1 2 3

Designation Electrical plug connection Fastening screws Rear lid

Qty. 1 4 1

Removal Press the lug of the electrical plug connection arrow and separate. Unscrew fastening screws.

Installation Plug in the electrical plug connection. Tightening torque: 10 Nm (7.5 ftlb.) Adjust lid to the hinges in accordance with the contours of the wings and the rear spoiler. => Gap dimensions, body rear &ndash; Carrera 4S

996430, 996431

55 90 19 Removing and installing rear lid Carrera 4S

2015

55 90 37 Disassembling and assembling rear lid Carrera 4S

Disassembling rear lid Assembling rear lid Removing 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 values Tightening torques Materials and tools

55 90 37 Disassembling and assembling rear lid

Carrera 4S

2016

einordnung top of page

Disassembling rear lid

No. Procedure 1 Removing upper part of the spoiler Removing the folding wall from the upper part of the spoiler

Instructions Extend spoiler manually. Press out the plastic 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 . 1. Press out the expanding rivets 4 . 2. Remove the rails 5 from the lower part of the spoiler towards the rear. 3. 2017

3 Disassembling rear lid

einordnung Removing the folding wall from the cover Press out the clamping washer 7 with a screwdriver. The clamping washers are destroyed by the action of removing them. 4. Remove the fastening rail 8 and the folding wall 6 from the cover towards the rear.

Removing the lower part of the 5. => Removing and installing additional brake light spoiler 6. Unscrew the fastening nuts 9 from the upper part of the spoiler and the hinge 11 . Remove the threaded plate 10 . 7. Unscrew the fastening screws 12 from the lower part of the spoiler and the actuating element. Remove the position spacer 13 . Removing hinge Unscrew fastening screws 14 from the hinge 11 .

Disassembling rear lid

2018

einordnung Instructions Unscrew fastening screws 15 and 16 from the actuating element 17 . 7 Removing rubber covering Pull rubber cover 18 out of the rear cover. 8 Removing adjusting Unscrew rubber pad 19 and unclip collar 20 . element 9 Removing upper part of Unscrew fastening screws 21 and remove upper part of lock 22 . the lock 10 Removing fan with fan Disconnect plug connections for fan and engine compartment lighting housing on the fan housing. See: => Removing and installing wiring harness Unscrew fastening screws 23 and remove fan with fan housing 24 . 11 Removing air guide Pull off air guide 25 from the rear cover. 12 Removing model logo Pull off model logo 26 . Removing reflector cover => Removing and installing reflector cover No. Procedure 6 Removing the mount

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Assembling rear lid

Assembling rear lid

2019

einordnung

No. 1 2 3

Procedure Sticking on model logo Installing air guide Fitting fan with fan housing

5 6

Instructions => Replacing the model logo Position the air guide 25 on the rear cover and insert. Position fan with fan housing 24 , screw down with fastening screws 23 . => Tightening torques Connect plugs for fan and engine compartment lighting on the fan housing. See: => Removing and installing wiring harness Fitting upper part of the Position upper part of the lock 22 and fasten with fastening lock screws 21 . => Tightening torques Installing adjusting element Engage collar 20 . Screw in rubber pads 19 . Fitting rubber covering Position the rubber covering 18 on the rear cover and push in. => Installing rubber covering Cabriolet 2020

Assembling rear lid

einordnung Installing wiring harness Fitting mount => Removing and installing wiring harness Position the mount 17 on the rear cover and screw in using the fastening screws 15 and 16 . => Tightening torques

No. Procedure 8 Fitting hinge 9 Mounting the lower part of the spoiler

Instructions Position hinge 11 and screw in using the fastening screws 14 . => Tightening torques 1. Position the spacer 13 on the lower part of the spoiler. Tighten the fastening screws 12 . 2. Position the upper part of the spoiler on the hinge 11 . Using the threaded plate 10 and the fastening nuts 9 securely screw down the upper part of the spoiler. => Tightening torques

Assembling rear lid

2021

einordnung 10 Mounting the folding wall on the cover 3. Position the fastening rail 8 on the folding wall 6 and the rear cover. 4. Put new clamping washers 7 on the pegs of the fastening rail.

11 Mounting the the folding 5. Insert the rail 5 with the folding wall into the lower part wall on the upper part of the of the spoiler in direction of arrow . spoiler 6. Press in the expanding 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 locking tabs inset V have engaged. 9. Screw down the clamping screws 2 . => Tightening torques Push in the plastic plugs 1 .

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Removing and installing additional brake light

1. Removing additional brake light a. Unclip cover A at the sides, unlock lock B . Remove brake light and disconnect plug connection C .

Removing and installing additional brake light

2022

einordnung

1. Installing additional brake light a. Push on plug C . Insert brake light. Lock the lock B . Clip in the cover A . top of page

Installing rubber 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 dimension X = 0.5 mm and stick flush into the lid over the entire length. top of page

Installing rubber covering Cabriolet

2023

einordnung

Removing and installing reflector cover

Removing reflector cover Unscrew fastening screw 27 from the reflector cover 28 . Install reflector cover Secure the reflector cover 28 with the fastening screws 27 . => Tightening torques => Test and adjustment values top of page

Removing and installing wiring harness

Removing wiring harness 1 Press the lug of the electrical plug connection, see inset arrow and separate. 2 Remove additional brake light. See: => Removing and installing additional brake light. 3 Pull out grommet A with brake light lead. Disconnect 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. Installing wiring harness 1 Lay the wiring harness and mount with the fastening clips from the inner side of the mount in the positions specified arrows . Connect the plug C for the engine compartment lighting and B for the engine compartment fan. Push the plug with the grommet A through the opening in the rear lid until the grommet can be pushed into place. 2 Plug in the electrical plug connection. 3 Install additional brake light. See: => Removing and installing additional brake light. Removing and installing reflector cover 2024

einordnung top of page

Replacing the model logo

1. Find the middle of the lid. 2. Position logo Carrera with the dimensions A = 185 mm and B = 31 mm on the rear lid and affix. 3. Position logo S with the dimensions C = 185 mm and B = 29 mm on the rear lid and affix. 4. Insert logo 4 in the external cut opening 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 Rear lid to rear trim

Dimension H 5 2 J 2.2+0.5
1.5

Note mm mm Rear lid only lowered mm mm Rear lid only lowered mm Tail light only lowered (max. 1 mm) mm Rear lid only lowered (max. 1 mm). determine

K L Rear lid to tail light Rear lid to outer side M N

5 2 1.8+0.5
1.5

4.5 1 4.5 1

Removing and installing wiring harness

2025

einordnung section left to right

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Tightening torques

Location Fastening screws of upper part of spoiler on lower part of spoiler Fastening screws of spacer on mount Fastening screws of threaded plate on hinge Fastening screws of hinge on rear cover Fastening screws of mount on rear cover Fastening screws of upper part of lock on rear cover Fastening screws fan with housing to rear cover Fastening screws of reflector cover on rear lid

Tightening torque [Nm] Illustration Thread (ftlb.) 5 10 (7.5) Nm (ftlb.) 9 12 14 15, 16 21 23 27 M6 M6 M6 M6 M6 M6 M5 10 (7.5) Nm (ftlb.) 10 (7.5) Nm (ftlb.) 10 (7.5) Nm (ftlb.) 10 (7.5) Nm (ftlb.) 10 (7.5) Nm (ftlb.) 10 (7.5) Nm (ftlb.) 4 (3) Nm (ftlb.)

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Materials and tools

Item

Designation Cleaning agent

Source See Parts Catalogue in Main Group 8/03/05

Remarks

996430, 996431, 996630, 996631

Test and adjustment values

2026

55 91 19 Removing and installing rear lid hinges Carrera 4S

55 91 19 Removing and installing rear lid hinges Carrera 4S

2027

einordnung

No. Designation 1 Pneumatic spring left/right 2 Retainer 3 4 5 6

Qty. Removal 2

Installation

Press out with a narrow screwdriver.

Press in.

Stop clip 2 left/right Collar nut 4 M6 Lid hinge, right 1 Lid hinge, left 1

Tightening torque: 10 Nm (7.5 ftlb.) Loosen collar nut 4 . Loosen collar nut 4 . Adjust to the right side section in accordance with lid contour. Adjust to the left side section in accordance with lid contour.

55 91 19 Removing and installing rear lid hinges Carrera 4S

2028

einordnung

996430, 996431

55 91 19 Removing and installing rear lid hinges Carrera 4S

2029

19 58 19 Removing and installing coolant regulator

Removal overview of the coolant regulator Installation 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

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Removal overview of the coolant regulator

19 58 19 Removing and installing coolant regulator

2030

einordnung

1 2 3 4

Drain coolant Remove closure cap Remove coolant regulator housing Remove coolant regulator

1. Drain coolant a. Removal overview of the coolant regulator 2031

einordnung Open lid on the expansion tank. Undo the drain plug on the two necks for coolant and collect the coolant. After draining the coolant, fit new sealing rings on the drain plug arrow . Tightening torque: 10 to 15 Nm (7.5 to 11 ftlb.)

2. Remove closure cap Remove the closure cap arrow on the cylinder head over the oil extraction pump of the cylinder bank 1 to 3. To do this, remove the three hexagonhead bolts and remove the closure cap.

3. Remove coolant hose Unclip the coolant hose on the housing of the coolant regulator with a screwdriver and pull the coolant hose up and off.

4. Remove coolant regulator housing b. Undo the three fastening screws arrow of the coolant regulator housing. c. Remove the coolant regulator housing. Note Do not use the seal again!

Removal overview of the coolant regulator

2032

einordnung

5. Remove coolant regulator d. Remove coolant regulator with assembly aid 9627 . e. Insert assembly aid between the sheetmetal edges as shown. Push the assembly aid against the spring force until the retaining bracket is released. f. Turn coolant regulator by approx. 90 and take coolant regulator out of the housing. top of page

Installation overview of the coolant regulator

Installation overview of the coolant regulator

2033

einordnung

1 2 3 4 5

Install coolant regulator Install coolant regulator housing Push on coolant hose Install closure cap Bleed coolant circuit

1. Install coolant regulator. Installation overview of the coolant regulator 2034

einordnung a. Insert coolant regulator in the housing as shown. b. Push against the spring force using assembly aid 9627 and turn until both sheetmetal edges are touching the housing.

2. Install coolant regulator housing c. Clean sealing surfaces. d. 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 with a new seal into the coolant regulator housing. h. Push hose downwards until the retaining clip is heard to engage. i. Pull the hose slightly to check for secure seating.

Installation overview of the coolant regulator

2035

einordnung

4. Install closure cap. j. Reinstall the closure cap arrow beside the oil extraction pump on the cylinder bank 1 to 3. k. Lightly coat the Oring with acidfree grease. l. Press in the closure 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 carefully. To do this, lift the bow on the closure cap.

996420, 996421, 996450, 996451, 996620, 996621, 996650, 996651, 996840, 996841

Installation overview of the coolant regulator

2036