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1998-2005 Porsche 911 Carrera (996) Repair Manual – PDF DOWNLOAD
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1998-2005 Porsche 911 Carrera (996) Repair Manual – PDF DOWNLOAD
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Description
1998-2005 Porsche 911 Carrera (996) Repair Manual – PDF DOWNLOAD
FILE DETAILS:
1998-2005 Porsche 911 Carrera (996) Repair Manual – PDF DOWNLOAD
Language : English
Pages : 2342
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
1998-2005 Porsche 911 Carrera (996) Repair Manual – PDF DOWNLOAD
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.
Structure:
- Overview of repair groups
- Contents
- Technical data / general
- Descriptiono f repairs
Breakdown of Repair Groups:
- Tools, special tools and materials required for repair
- Explodedd rawinga nd illustrationo f sequence
- Legend for exploded drawing and description of sequence
- Instructionsfo r assemblya nd adjustment
TABLE OF CONTENTS:
1998-2005 Porsche 911 Carrera (996) Repair Manual – PDF DOWNLOAD
996 Workshop.......................................................................................................... 1 Entire Vehicle - General.......................................................................................... 0 General....................................................................................................... 11 Technical Data............................................................................................ 12 Lifting the vehicle....................................................................................... 26 Power unit................................................................................................ 27 Transmission.............................................................................................. 29 Running Gear.............................................................................................. 31 Body...................................................................................................... 40 Electrics................................................................................................. 49 Power supply - general (work instructions after disconnecting the battery)................................ 53 Technical data - GT3...................................................................................... 0 Sales Check................................................................................................... 57 Deactivating the transport lock........................................................................... 57 Activating the parking aid................................................................................ 58 Fitting front lip - GT3................................................................................... 60 Fitting roll-over bar (cage) - GT3........................................................................ 61 Fitting six-point seat belt - GT3......................................................................... 63 Removing transport lock (spring strut locking devices) - Carrera and GT3.................................. 65 Maintenance................................................................................................... 66 Maintenance schedule...................................................................................... 66 Maintenance............................................................................................... 69 Maintenance - GT3......................................................................................... 94 Diagnosis, Part 1 (up to Repair Group 45)......................................................................... 0 General....................................................................................................... 5 Installation location, diagnositc socket.................................................................. 6 Operating instructions, Porsche System Tester 2........................................................... 7 DME........................................................................................................... 15 System M 11............................................................................................... 15 Programming DME control module............................................................................ 17 Tiptronic..................................................................................................... 23 System G 50............................................................................................... 23 Anti-lock brake system diagnosis.............................................................................. 64 System PSM 5.3 and ABS/TC 5.3............................................................................. 64 PSM........................................................................................................... 115 System PSM 04............................................................................................. 115 System PSM 05XX........................................................................................... 243 Diagnosis, Part 2 (as of Repair Group 61)......................................................................... 0 Convertible-top diagnosis..................................................................................... 6 System B 3.2.............................................................................................. 6 Airbag Diagnosis.............................................................................................. 26 System B 04............................................................................................... 26 Airbag Diagnosis.............................................................................................. 68 System B 05............................................................................................... 68 Roll-over protection system diagnosis......................................................................... 47 System UEB11.............................................................................................. 47 Seat memory diagnosis......................................................................................... 89 System S 01............................................................................................... 89 Heating diagnosis............................................................................................. 131 System H 01............................................................................................... 131 Alarm system diagnosis........................................................................................ 167 System I 32............................................................................................... 167 Instrument cluster diagnosis.................................................................................. 241 System K 0X............................................................................................... 241 PCM diagnosis................................................................................................. 319 System N 01............................................................................................... 319 ParkAssistent diagnosis....................................................................................... 295 System P 01............................................................................................... 295 Headlight beam adjustment diagnosis........................................................................... 356 System HBA 01............................................................................................. 356 Engine, Part 1 (up to Repair Group 13)............................................................................ 0 Engine........................................................................................................ 10 Tightening torques for engines M96/01..................................................................... 11 3.4 l engine performance kit / X51........................................................................ 14 Engine - Crankcase, suspension................................................................................ 28 Removing and installing engine (vehicle with Tiptronic transmission)...................................... 28 Disassembling and assembling engine....................................................................... 48 Disassembling and assembling crankcase halves............................................................. 78 Removing and installing engine - GT3...................................................................... 88 Disassembling and assembling engine - GT3................................................................. 99 Disassembling and assembling crankcase - GT3.............................................................. 116 Removing cylinder - GT3................................................................................... 140 Engine - Crankshaft, pistons.................................................................................. 141 Removing and installing drive belt........................................................................ 141 Removing and installing deflection rollers for drive belt................................................. 144 Removing and installing tensioning roller for drive belt.................................................. 145 Removing and installing belt tensioner.................................................................... 146 Disassembling and assembling belt tensioner............................................................... 156 Disassembling and assembling bearing housing with crankshaft.............................................. 159 Removing and installing crankshaft sealing ring........................................................... 164 Removing and installing crankshaft sealing ring - engine installed........................................ 175 Removing and installing pistons........................................................................... 184 Removing and installing drive belt - GT3.................................................................. 211 Disassembling and assembling belt tensioner - GT3......................................................... 220 Disassembling and assembling crankshaft - GT3............................................................. 224 Removing and installing pistons - GT3..................................................................... 231 Installing pistons - GT3.................................................................................. 235 Installing piston pin with piston-pin circlip - GT3....................................................... 241 Engine, Part 2 (as of Repair Group 15)............................................................................ 0 Engine - Cylinder head, valve drive........................................................................... 6 Diasassembling and assembling cylinder head - Inner parts................................................. 8 Removing and installing valve springs..................................................................... 13 Removing and installing valve stem seal................................................................... 15 Installing cylinder head.................................................................................. 16 Disassembling and assembling cylinder head - Camshaft drive............................................... 20 Removing and installing camshafts......................................................................... 27 Installing camshafts.................................................................................. 31 Adjusting timing - cylinder bank 1 - 3................................................................ 42 Adjusting timing - cylinder bank 4 - 6................................................................ 45 Removing and installing valve tappets - engine removed.................................................... 49 Removing valve tappets of cylinder bank 1 - 3......................................................... 52 Installing valve tappets - Cylinder bank 1 - 3........................................................ 55 Removing valve tappets of cylinder bank 4 - 6......................................................... 60 Installing valve tappets - Cylinder bank 4 - 6........................................................ 63 Completing camshafts...................................................................................... 69 Sealing cover for camshaft housing (cylinder head cover).................................................. 74 Checking guide for valve tappets.......................................................................... 77 Removing and installing oil protection tube (engine installed)............................................ 78 Removing and installing valve tappets (engine installed).................................................. 83 Removing valve tappets of the cylinder bank 1 - 3 (engine installed).................................. 87 Installing valve tappets of the cylinder bank 1 - 3 (engine installed)................................ 92 Adjusting timing of cylinder bank 1 - 3 (engine installed)................................................ 94 Removing valve tappets of the cylinder bank 4 - 6 (engine installed)...................................... 97 Installing valve tappets of the cylinder bank 4 - 6 (engine installed).................................... 100 Adjusting timing of cylinder bank 4 - 6 (engine installed)................................................ 102 Removing and installing closure cap for camshaft bore (engine installed).................................. 106 Checking camshaft (timing) (engine installed)............................................................. 110 Removing and installing sealing ring for intermidiate shaft (engine installed)............................ 117 Removing and installing solenoid hydraulic valve.......................................................... 122 Reworking cylinder head................................................................................... 123 Removing and installing camshaft housing - GT3............................................................ 124 Removing camshaft housing - GT3....................................................................... 125 Installing camshaft housing - GT3..................................................................... 133 Removing and installing cylinder head - GT3............................................................... 145 Removing cylinder head - GT3.......................................................................... 146 Installing cylinder head - GT3........................................................................ 155 Disassembling and assembling intermediate shaft - GT3..................................................... 164 Engine - Lubrication.......................................................................................... 167 Removing and installing air/oil separator................................................................. 167 Removing and installing oil pump with coolant guide housing............................................... 171 Removing and installing oil extraction pumps.............................................................. 179 Removing and installing oil extraction pump (engine installed)............................................ 181 Removing and installing oil-water heat exhanger - Engine installed........................................ 187 Removing and installing oil pan (engine installed)........................................................ 192 Removing and installing oil filler neck................................................................... 195 Removing oil extraction pump - GT3........................................................................ 200 Disassembling and assembling oil extraction pump -GT3..................................................... 205 Installing oil extraction pump - GT3...................................................................... 214 Removing and installing oil cooler - GT3.................................................................. 219 Removing and installing bracket for oil cooler - GT3...................................................... 231 Removing bracket for oil cooler - GT3................................................................. 232 Installing bracket for oil cooler - GT3............................................................... 245 Removing and Installing oil temperature sensor - GT3...................................................... 258 Engine - Cooling.............................................................................................. 261 Draining and topping up with coolant...................................................................... 261 Removing and installing coolant regulator................................................................. 265 Removing and installing cooling pump...................................................................... 268 Coolant warning light in instrument cluster............................................................... 276 Removing coolant pump (engine installed) - GT3............................................................ 277 Installing coolant pump (engine installed) - GT3.......................................................... 283 Removing and installing coolant regulator - GT3........................................................... 289 Removing and installing housing for coolant guide - GT3................................................... 298 Removing housing for coolant guide - GT3.............................................................. 299 Installing housing for coolant guide - GT3............................................................ 311 Removing and installing temperature sensor for coolant - GT3.............................................. 323 Oil/coolant mixing........................................................................................ 325 Checking the cooling system for leaks..................................................................... 326 Removing and installing coolant hoses - GT3............................................................... 328 Removing coolant hoses................................................................................ 329 Installing coolant hoses.............................................................................. 338 Tightening torques.................................................................................... 348 Fuel, exhaust, engine electronics................................................................................. 0 Fuel supply, control.......................................................................................... 5 Checking fuel pressure.................................................................................... 6 Checking quantity delivered by fuel pump.................................................................. 8 Removing and installing fuel pump......................................................................... 9 Calibrating fuel level sensor system...................................................................... 12 Removing and installing fuel filler neck.................................................................. 13 Removing and installing fuel tank......................................................................... 17 Calibrating fuel level sensor system - GT3................................................................ 27 Fuel system, electronic injection............................................................................. 28 Disassembling and assembling fuel ring pipe............................................................... 28 Disassembling and assembling intake distributor........................................................... 31 Programming DME control module............................................................................ 36 Disassembling and assembling intake distributor - GT3..................................................... 39 Exhaust system................................................................................................ 46 Removing and installing exhaust system - GT3.............................................................. 46 Removing exhaust system - GT3......................................................................... 47 Installing exhaust system - GT3....................................................................... 52 Removing and installing catalytic converters (engine installed)........................................... 57 Starter, power supply, cruise control......................................................................... 64 Removing and installing starter........................................................................... 64 Removing and installing three-phase generator............................................................. 66 Removing and installing cruise control actuator.......................................................... 68 Removing and installing starter - GT3..................................................................... 70 Removing and installing three-phase generator - GT3....................................................... 71 Removing and installing bracket for oil generator - GT3................................................... 73 Work instructions after disconnecting the battery......................................................... 82 Ignition system............................................................................................... 86 Removing and installing ignition switch................................................................... 86 Removing spark plugs - GT3................................................................................ 88 Installing spark plugs - GT3.............................................................................. 89 Transmission, manual transmission................................................................................. 0 911 Carrera (996)............................................................................................. 0 Transmission.............................................................................................. 10 Technical data........................................................................................ 11 6-Speed manual transmission G96/30................................................................ 11 Manual transmission tightening torques........................................................ 13 Front wheel drive Z96.00.......................................................................... 14 Front-axle drive tightening torques............................................................... 18 Clutch, control........................................................................................... 19 Removing and installing clutch........................................................................ 19 Disassembling and assembling clutch................................................................... 21 Bleeding the clutch system............................................................................ 23 Removing and installing clutch slave cylinder......................................................... 23 Removing and installing clutch pedal.................................................................. 25 Clutch boost spring: allocation and grease specification.............................................. 33 Removing and installing release bearing - GT3......................................................... 37 Manual transmission - Actuation, ass. housing............................................................. 43 Changing transmission oil............................................................................. 43 Removing and installing transmission G 96............................................................. 44 Removing and installing the shift console............................................................. 48 Removing and installing shift and selector cables.................................................... 52 Removing and installing closure cap for selector force mechanism...................................... 0 Manual transmission - Gears, shafts, int. gearsh.......................................................... 72 Removing and installing sealing ring for input shaft.................................................. 59 Final drive - Differential, differential lock............................................................. 62 Removing and installing cover for final drive......................................................... 62 Removing and installing sealing ring for halfshaft flange of limited-slip differential................ 64 Removing and installing sealing ring for halfshaft flange of differential............................. 65 911 Carrera 4 (996)........................................................................................... 71 Power Transmission........................................................................................ 72 Technical data........................................................................................ 73 Final drive - Differential, differential lock............................................................. 79 Removing and installing front final drive............................................................. 79 Removing and installing cardan shaft.................................................................. 83 Removing and installing sealing ring for cardan flange................................................ 87 Removing and installing viscous clutch................................................................ 91 Checking function of installed viscous clutch......................................................... 95 Removing and installing sealing ring for flanged shaft................................................ 97 Removing and installing cover for final drive......................................................... 99 Changing oil for final drive.......................................................................... 102 Removing and installing support for final drive....................................................... 103 Repair.................................................................................................... 105 911 Carrera 4 (996)........................................................................................... 71 Power Transmission........................................................................................ 72 Technical data........................................................................................ 73 Final drive - Differential, differential lock............................................................. 79 Removing and installing front final drive............................................................. 79 Removing and installing cardan shaft.................................................................. 83 Removing and installing sealing ring for cardan flange................................................ 87 Removing and installing viscous clutch................................................................ 91 Checking function of installed viscous clutch......................................................... 95 Removing and installing sealing ring for flanged shaft................................................ 97 Removing and installing cover for final drive......................................................... 99 Changing oil for final drive.......................................................................... 102 Removing and installing support for final drive....................................................... 103 911 Carrera (996) GT3......................................................................................... 105 Power Transmsiion......................................................................................... 106 Technical data (GT3).................................................................................. 107 Manual transmission - Actuation, hausing.................................................................. 112 Removing and installing the transmission.............................................................. 112 Removing and installing closure cap for selector force mechanism...................................... 116 Disassembling and assembling transmission............................................................. 119 Disassembling and assembling front transmission cover................................................. 133 Disassembling and assembling gear housing............................................................ 135 Disassembling and assembling transmission housing..................................................... 139 Manual transmission - Gears, shafts, int. gearsh.......................................................... 146 Removing and installing sealing ring for input shaft.................................................. 146 Disassembling and assembling input shaft............................................................. 149 Removing and installing pinion shaft.................................................................. 154 Removing pinion shaft bearing......................................................................... 156 Final drive - Differential, differential lock............................................................. 157 Disassembling and assembling GKN differntial lock.................................................... 157 Removing and installing differential lock............................................................. 164 adjusting drive set................................................................................... 166 Transmission, automatic transmission.............................................................................. 0 911 Carrera (996)............................................................................................. 0 Transmission.............................................................................................. 10 Technical data........................................................................................ 12 5-speed Tiptronic transmission A96/30............................................................. 12 Tightening torques for Tiptronic transmission................................................. 13 Front wheel drive Z 96.00......................................................................... 14 Front-axle drive tightening torques........................................................... 14 Automatic clutch - Torque converter....................................................................... 22 Removing and installing torque converter.............................................................. 22 Removing and installing torque-converter sealing ring................................................. 24 Automatic transmission - Auction, ass. housing............................................................ 27 Removing and installing selector knob................................................................. 27 Adjusting selector lever cable........................................................................ 28 Removing and installing selector support.............................................................. 30 Removing and installing selector lever cable......................................................... 35 Removing and installing shiftlock solenoid............................................................ 39 Checking and topping up ATF fluid..................................................................... 44 Replacing ATF fluid................................................................................... 47 Removing and installing ATF filter.................................................................... 48 Removing and installing inner oil tube................................................................ 50 Removing and installing multi-function switch......................................................... 52 Removing and installing sealing ring for selector shaft............................................... 54 Removing and installing tiptronic transmission A 96/00................................................ 56 Automatic transmission - Gears, control................................................................... 64 Removing and installing hydraulic control unit........................................................ 64 Removing and installing wiring harness................................................................ 68 Removing and installing ATF cooler.................................................................... 70 Removing and installing sensor for transmission input speed........................................... 73 Removing and installing transmission speed sensor..................................................... 74 Removing and installing pressure regulator............................................................ 0 Final drive, differential, differential lock.............................................................. 75 Changing and checking transmission oil in final drive................................................. 75 Removing and installing differential.................................................................. 76 Removing and installing sealing ring for short flanged shaft.......................................... 78 Removing and installing long flanged shaft............................................................ 81 Removing and installing sealing ring for long flanged shaft........................................... 83 Removing and installing final drive/transmission housing double sealing ring.......................... 86 911 Carrera 4 (996)........................................................................................... 89 Transmission.............................................................................................. 90 Technical data........................................................................................ 91 Final drive - Differential, differential lock............................................................. 97 Removing and installing sealing ring for cardan flange................................................ 97 Running gear...................................................................................................... 0 911 Carrera (996)............................................................................................. 0 Running gear.............................................................................................. 6 Running gear - Overview: 911 Carrera (996)............................................................ 9 Stabaliser allocation................................................................................. 12 Removing spring strut locking devices - Carrera and GT3............................................... 14 Running gear, general - GT3........................................................................... 15 Notes on repair instructions - GT3.................................................................... 16 Tests / notes - GT3................................................................................... 18 Front wheel suspension, drive shafts...................................................................... 20 Tightening torques for front axle..................................................................... 20 Removing and installing front spring strut............................................................ 24 Removing and installing front spring strut - GT3...................................................... 26 Disassembling and assembling front spring strut....................................................... 31 Disassembling and assembling front spring strut - GT3................................................. 37 Removing and installing front wheel bearing........................................................... 42 Installing caster eccentric........................................................................... 48 Rear wheel suspension, drive shafts....................................................................... 50 Tightening torques for rear axle...................................................................... 50 Removing and installing rear spring strut............................................................ 53 Disassembling and assembling rear spring strut........................................................ 54 Disassembling and assembling rear spring strut - GT3.................................................. 62 Removing and installing rear wheel bearing............................................................ 68 Removing and installing rear tie rod (toe control arm)................................................ 74 Removing and installing rear wheel bearing housing (wheel carrier).................................... 76 Removing and installing drive shaft (manual transmission)............................................. 83 Removing and installing drive shaft (Tiptronic transmission).......................................... 89 Wheels, tires, suspension alignment....................................................................... 95 Wheels and tyres (tyre pressure / mounting wheel on vehicle).......................................... 95 Adjustment values for suspension alignment............................................................ 97 Alignment cards for Carrera (996) and GT3............................................................. 100 Complete suspension alignment......................................................................... 101 Suspension alignment GT3.............................................................................. 102 General tyre mounting instructions.................................................................... 118 Checking rims......................................................................................... 122 Identifying size for 18-inch Turbo wheels (Technologie wheels)........................................ 123 Tyre failure/tyre sealant - GT3....................................................................... 124 Tyre mounting for critical wheels/tyre pairs.......................................................... 126 Anti-Lock Brake System (ABS).............................................................................. 131 Important information on ABS 5.3 and ABS/TC 5.3....................................................... 131 ABS 5.3 system description............................................................................ 132 ABS/TC 5.3 system description......................................................................... 134 Component arrangement (ABS and ABS/TC)................................................................ 136 Function of individual components..................................................................... 137 ABS test with Porsche System Tester 2................................................................. 140 Removing and installing front speed sensor............................................................ 141 Removing and installing rear speed sensor............................................................. 142 Brakes - Brake mechanics.................................................................................. 143 Tightening torques for brake mechanics................................................................ 143 Technical data (brake disc wear limit)................................................................ 144 Technical data (brake disc wear limit) - GT3.......................................................... 146 measuring brake pad thickness......................................................................... 148 Removing and installing front disc brake pads........................................................ 149 Removing and installing rear disc brake pads......................................................... 151 Adjusting brake push rod.............................................................................. 153 Checking brake-light switch setting................................................................... 154 Adjusting parking brake shoes......................................................................... 156 Removing and installing front brake disc.............................................................. 158 Removing and installing rear brake disc............................................................... 160 Removing and installing parking brake shoes........................................................... 162 Measuring lateral runout of front brake discs......................................................... 165 Measuring lateral runout of rear brake discs.......................................................... 167 Removing and installing brake pedal.................................................................. 169 Brakes - Hydraulics, regulator, booster................................................................... 179 Tightening torques for brake hydraulics............................................................... 179 Bleeding brakes....................................................................................... 180 Changing brake fluid.................................................................................. 183 Steering.................................................................................................. 184 Tightening torques for steering....................................................................... 184 Test and assembly work on power steering.............................................................. 185 Removing and installing steering wheel (airbag)....................................................... 186 Replacing steering system after accident damage....................................................... 188 Removing and installing steering gear................................................................. 190 Plug couplings for steering hydraulics................................................................ 194 Removing and installing lock barrel................................................................... 199 Replacing steering lock............................................................................... 201 Removing and installing hydraulic pump................................................................ 209 911 Carrera 4 (996)........................................................................................... 219 Running gear.............................................................................................. 220 Overview of 911 Carrera 4 running gear................................................................ 221 Notes on repair instructions.......................................................................... 221 Tests/notes for all-wheel drive....................................................................... 222 Stabalizer allocation................................................................................. 223 Anti-Lock Brake System (ABS).............................................................................. 238 Overview of PSM references............................................................................ 238 Calibrating steering angle sensor..................................................................... 240 PSM component arrangement............................................................................. 243 Brakes - Brake mechanics.................................................................................. 254 Technical data (brake disc wear dimension)............................................................ 254 Brakes - Hydraulics, regulator, booster................................................................... 256 Bleeding brakes (vehicle with PSM).................................................................... 256 Changing brake fluid (vehicle with PSM)............................................................... 259 Body.............................................................................................................. 0 Body - general................................................................................................ 10 Safety instructions for body repair....................................................................... 14 Safety instructions for disassembling components...................................................... 14 Safety instructions for air conditioning.............................................................. 14 Safety instructions for fuel tank..................................................................... 14 Safety instructions for for paintwork, glass, upholstery, linings..................................... 15 Safety instructions for airbag system................................................................. 15 Safety instructions for door.......................................................................... 15 Safety instructions for sliding roof.................................................................. 17 Safety instructions for rear spoiler.................................................................. 17 Safety instructions for rear window................................................................... 17 Safety instructions for windscreen.................................................................... 18 Safety instructions for heat shields.................................................................. 19 Safety instructions for cabriolet convertible top..................................................... 19 Safety instructions for roll-over protection system................................................... 20 Safety instructions for plug location plan (body)..................................................... 20 Safety instructions for water drains (body)........................................................... 20 Safety instructions for welding....................................................................... 20 Safety instructions for Teromix-6700 two-component adhesive........................................... 21 Safety instructions for hydraulic system.............................................................. 21 Safety instructions for hardtop....................................................................... 21 Safety instructions for belt strap holder............................................................. 22 General information and quality notes..................................................................... 23 Electronic control modules............................................................................ 23 - Protection against overvoltage.................................................................. 23 - Replacing control modules....................................................................... 23 Tools and metalworking tools for body repairs............................................................. 24 Straightening systems................................................................................. 24 Metalworking tools.................................................................................... 25 - Electrical equipment............................................................................ 25 - Mechanical equipment............................................................................ 25 - Compressed-air equipment........................................................................ 26 - Welding equipment............................................................................... 27 Check dimensions for body repair.......................................................................... 28 Floor assembly control dimensions for the 996 Carrera model up to model year 2000..................... 28 Floor assembly control dimensions for the the GT3 model............................................... 29 Floor assembly control dimensions for the 996 Carrera model from model year 2001...................... 30 Body parts of high-strength steel......................................................................... 37 Water drainage plan....................................................................................... 43 Water drainage plan - Cabriolet........................................................................... 44 Check dimensions for body repair - Cabriolet structure.................................................... 45 Plug location plan........................................................................................ 48 Diagram - body gap dimensions............................................................................. 56 Diagram - keys to symbols for welding work................................................................ 60 Resistance spot welding............................................................................... 60 Inert-gas arc welding (MAG procedure)................................................................. 60 Gas welding........................................................................................... 60 Seam seals................................................................................................ 61 Accessories........................................................................................... 62 - Front lid....................................................................................... 62 - Doors........................................................................................... 63 - Sliding roof panel.............................................................................. 63 - Rear lid........................................................................................ 64 Work sequence for accident repair......................................................................... 65 Body front.................................................................................................... 67 Removing and installing wheel housing liner............................................................... 67 Removing and installing the wing.......................................................................... 70 Replacing closing panel................................................................................... 75 Cutting out closing panel and front floor panel....................................................... 76 Preparing closing panel and front floor panel for installation and fitting............................ 78 Welding in closing panel and front floor panel........................................................ 80 Tools and materials................................................................................... 81 Replacing wheel housings and side members (sectional repair).............................................. 82 Cutting out wheel housings and side member............................................................ 83 Preparing wheel housings and side members for installation and fitting................................ 85 Welding in wheel housing and side members............................................................. 87 Replacing wheel housings.................................................................................. 89 Removing wheel housing, lower shell and outer side member from the body............................... 90 Preparing wheel housing, lower shell and outer side member for installation and fitting............... 92 Welding wheel housing, lower shell and outer side members into the body............................... 94 Tools and materials................................................................................... 95 Cleaning front water drains on Coupe and Cabriolet........................................................ 97 Replacing front wall...................................................................................... 100 Cutting out front wall................................................................................ 101 Preparing front wall for installation and fitting..................................................... 103 Welding in front wall................................................................................. 105 Tools and materials................................................................................... 106 Replacing front wall - Carrera 4 / GT 3................................................................... 107 Cutting out front wall................................................................................ 108 Preparing front wall for installation and fitting..................................................... 110 Welding in front wall................................................................................. 112 Tools and materials................................................................................... 113 Body centre, roof, frame...................................................................................... 114 Removing and installing underbody cover................................................................... 114 Repalcing rear centre panel............................................................................... 117 Removing and installing deformation element............................................................... 123 Replacing roof............................................................................................ 126 Disconnecting roof.................................................................................... 127 Preparation of roof for installation and fitting...................................................... 129 Welding in roof....................................................................................... 131 Tools and materials................................................................................... 132 Replacing lower side member............................................................................... 134 Cutting out lower side member......................................................................... 135 Preparation for installation of lower side member and fitting......................................... 137 Welding in lower side member.......................................................................... 139 Tools and materials................................................................................... 140 Replacing lower side member - Cabriolet................................................................... 141 Cutting out lower side member......................................................................... 142 Preparation for installation of lower side member and fitting......................................... 144 Welding lower side memeber............................................................................ 146 Tools and materials................................................................................... 147 Replacing seat cross member............................................................................... 148 Cutting out seat cross member......................................................................... 149 Preparation of seat cross member for installation and fitting......................................... 151 Welding in seat cross member.......................................................................... 153 Tools and materials................................................................................... 154 Body rear..................................................................................................... 155 Removing and installing wheel housing liner............................................................... 155 Cleaning rear water drains on Coupe and Cabriolet......................................................... 158 Replacing side section.................................................................................... 161 Replacing side section - Cabriolet........................................................................ 173 Replacing rear closing panel.............................................................................. 182 Replacing rear closing panel - GT 3....................................................................... 187 Cutting out rear closing panel........................................................................ 188 Preparing the rear closing panel for installation and fitting......................................... 190 Welding in rear closing panel......................................................................... 192 Tools and materials................................................................................... 193 Lids.......................................................................................................... 195 Disassembling and assembling front lid.................................................................... 195 Disassembling and assembling rear lid..................................................................... 199 Disassembling and assembling release for front lid - up to model year 2000................................ 205 Disassembling and assembling release for rear lid - up to model year 2000................................. 210 Disassembling and assembling rear lid - GT3............................................................... 215 Disassembling and assembling release for front lid - as of model year 2001................................ 221 Disassembling release for front lid................................................................... 222 Assembling release for front lid...................................................................... 224 Disassembling and assembling release for rear lid - from model year 2001................................. 226 Disassembling release for rear lid.................................................................... 227 Assembling release for rear lid....................................................................... 229 Door front, central locking system............................................................................ 231 Removing and installing door.............................................................................. 231 Disassembling and assembling door......................................................................... 236 Disassembling door.................................................................................... 237 Assembling door....................................................................................... 242 Adjustment instructions for assembly of the door.......................................................... 248 Diagram: sheetmetal clips and grommets................................................................ 248 Basic setting of door lock............................................................................ 248 - Basic setting of the door lock before installation.............................................. 249 Standardising the system.............................................................................. 249 - Standardising the power windows................................................................. 249 - Blockage detection function..................................................................... 250 - Precondition for operation of the power windows................................................. 250 Fitting the door window in the clamping jaws.......................................................... 250 Adjusting the door window angle in the vehicle's longitudinal direction............................... 251 Adjusting the door window height...................................................................... 251 - Adjustment procedure:........................................................................... 251 - Checking the adjustment:........................................................................ 252 Adjustment of the door window pressing force on the door seal at the top and sides.................... 252 - Adjustment procedure:........................................................................... 228 Checking the adjustement:......................................................................... 252 Adjusting the lower stop of the power window unit..................................................... 253 Disassembling and assembling door handle.................................................................. 258 Setting the door.......................................................................................... 261 Removing and installing inner door release (bowden cable) for door lock................................... 264 Removing and installing door handle....................................................................... 267 Removing and installing orientation lighting (LED light-emitting diodes).................................. 270 Removing orientation lighting (LED light-emitting diodes)............................................. 270 Installing orientation lighting (LED light-emitting diodes)........................................... 272 Body equipment, exterior.......................................................................................... 0 Body equipment................................................................................................ 10 Colour range for 1998 models.............................................................................. 13 Colour range for 1999 models.............................................................................. 14 Colour range for 2000 models.............................................................................. 16 Colour range for 2001 models.............................................................................. 17 Exterior paintwork solid.............................................................................. 17 Exterior paintwork metallic / pearl................................................................... 17 Processing of Porsche 2-component window bonding agents................................................... 18 Overview of tools and materials....................................................................... 18 Mixing procedure...................................................................................... 19 Sliding roof.................................................................................................. 22 Removing and installing sliding roof panel................................................................ 22 Removing and installing lifting/sliding roof drive........................................................ 30 Re-teaching the lifting/sliding roof drive................................................................ 32 Removing and installing frame for sliding roof............................................................ 33 Disassembling and assembling frame for sliding roof....................................................... 38 Convertible top, hardtop...................................................................................... 43 Removing and installing convertible top................................................................... 43 Diagram of convertible top............................................................................ 44 Overview of convertible-top components................................................................ 46 Removing convertible top.............................................................................. 48 Installing convertible top............................................................................ 52 Removing and installing water collection tray............................................................. 56 Removing and installing convertible-top compartment lid................................................... 60 Replacing convertible-top covering........................................................................ 66 Adjusting Cabriolet convertible top....................................................................... 84 Convertible top repair - after emergency operation........................................................ 88 Removing and installing rear side section flap............................................................ 95 Removing and installing hydraulic cylinders............................................................... 100 Removing and installing convertible-top control module.................................................... 105 Removing and installing convertible-top compartment lid drive............................................. 107 Removing and installing hardtop........................................................................... 108 Disassembling and assembling hardtop...................................................................... 114 Replacing convertible-top frame........................................................................... 136 Removing and installing micro switch for convertible-top compartment lid.................................. 151 Removing and installing micro switch for rear side section flap........................................... 152 Removing and installing additional flap................................................................... 154 Assembly instructions for hardtop assembly fixture........................................................ 157 Converting hinge from convertible-top compartment lid (Cabriolet)......................................... 163 Removing and installing potentiometer for convertible-top interrogation................................... 165 Removing and installing motor for rear side section flap................................................. 167 Calibrating convertible top............................................................................... 168 Adjusting the hardtop..................................................................................... 169 Care and cleaning of the convertible top.................................................................. 174 Cleaning the convertible top.......................................................................... 174 Care of convertible top............................................................................... 175 Care of convertible-top seals......................................................................... 176 Bumpers....................................................................................................... 177 Removing and installing front spoiler..................................................................... 177 Removing and installing rear spoiler...................................................................... 183 Removing and installing front spoiler - GT 3.............................................................. 190 Glazing, window control....................................................................................... 195 Removing and installing windscreen........................................................................ 195 Removing the windscreen............................................................................... 196 Fitting the windscreen................................................................................ 199 Overview of tools and materials....................................................................... 202 Removing and installing side window....................................................................... 204 Removing and installing rear window....................................................................... 209 Removing and installing rear window (hardtop)............................................................. 217 Removing and installing flexible rear window of Cabriolet................................................. 225 Removing and installing rear power windows (Cabriolet).................................................... 232 Removing and installing rear side window (Cabriolet)...................................................... 239 Removing and installing rear side window seal (Cabriolet)................................................. 241 Removing and installing power window motor................................................................ 242 Checking function of heating for rear window.............................................................. 244 Exterior equipment............................................................................................ 245 Disassembling and assembling the rearview mirror.......................................................... 245 Removing and installing roof joint strip.................................................................. 248 Removing and installing sill cover - GT 3................................................................. 253 Checking function of heating for mirror glass............................................................. 262 Interior equipment............................................................................................ 263 Removing and installing the interior rearview mirror...................................................... 263 Bonding the interior rearview mirror...................................................................... 266 Removing and installing centre console.................................................................... 270 Removing and installing sun visors........................................................................ 274 Disassembling and assembling sun visors................................................................... 277 Removing and installing inner sill (driver's side) - as of model year 2001................................ 282 Disassembling release for front lid................................................................... 283 Assembling release for front lid...................................................................... 285 Removing and installing inner sill (passenger's side)..................................................... 287 Removing inner sill................................................................................... 288 Installing inner sill................................................................................. 290 Passenger protection.......................................................................................... 292 Safety regulations for airbag vehicles.................................................................... 292 Disposal of airbag units.................................................................................. 296 Removing and installing the driver's airbag unit.......................................................... 301 Removing and installing the contact unit.................................................................. 302 Removing and installing the triggering unit for the airbag................................................ 303 Removing and installing the passenger's airbag unit....................................................... 304 Removing and installing the side airbag unit.............................................................. 306 Removing and installing roll-over bar..................................................................... 308 Removing and installing frame for roll-over protection system............................................. 315 Removing and installing control module for roll-over protection system.................................... 319 Removing and installing roll-over bar - GT 3 - up to model year 2000...................................... 320 Removing and installing roll-over bar - GT 3 - up to model year 2001...................................... 329 Removing roll-over bar................................................................................ 330 Adjusting roll-over bar............................................................................... 338 Assembly instructions for the rear trim, the floor covering and the closure caps...................... 340 Body equipment, interior.......................................................................................... 0 Body equipment, interior...................................................................................... 0 Special notes for the care of soft-lock paint surfaces.................................................... 12 Light soiling (e.g. dust)............................................................................. 12 Heavy soiling (e.g. oily, greasy dirt)................................................................ 12 Linings, insulation........................................................................................... 14 Disassembling and assembling the dashboard................................................................ 14 Disassembling the dashboard........................................................................... 15 - Removing the regulator for wiping interval...................................................... 21 - Removing the cigarette lighter.................................................................. 21 Assembling the dashboard.............................................................................. 22 - Installing the regulator for wiping interval.................................................... 28 - Instaling the cigarette lighter................................................................. 28 Removing and installing the dashboard..................................................................... 29 Removing and installing door trim panel................................................................... 33 Remove door trim panel................................................................................ 34 Install door trim panel............................................................................... 36 Additional assembly notes on bowden cable variant A and inner door handle............................. 37 - Up to Veh. Ident. Nos. Bowden cable variant A................................................... 38 - Up to Veh. Ident. Nos. Inner door handle variant A.............................................. 38 - Removal and installation of bowden cable variant A.............................................. 38 Assembly note on door film for vehicles without side airbag........................................... 39 Fitting sliding strip on the inner door panel......................................................... 39 Removing and installing oddments compartment lid.......................................................... 41 Removing and installing oddments compartment lid...................................................... 41 Removing and installing cowl panel cover.................................................................. 44 Removing and installing roof lining - cabriolet........................................................... 48 Removing and installing side-panel lining................................................................. 57 Removing side-panel lining............................................................................ 58 Installing side-panel lining.......................................................................... 60 Removing and installing trim of A, B and C-pillars........................................................ 67 Removing and installing trim of A, B and C-pillars.................................................... 68 Installing trim of A, B and C-pillars................................................................. 70 Removing and installing roof lining....................................................................... 72 Seat frames................................................................................................... 79 Removing and installing front seat........................................................................ 79 Removing front seat................................................................................... 80 Installing front seat................................................................................. 82 Removing and installing bucket seat - GT3................................................................. 84 Air conditioning.................................................................................................. 0 Air conditioning.............................................................................................. 5 Technical data for the air conditioning system............................................................ 6 Heating....................................................................................................... 7 Removing and installing heat exchanger.................................................................... 7 Ventilation................................................................................................... 8 Removing and installing mechanical heating / fresh air control............................................ 8 Removing and installing heating / fresh air unit.......................................................... 9 Installing and adjusting bowden cables of the heating/fresh-air control................................... 13 Removing and installing heater/fresh-air blower motor..................................................... 16 Removing and installing drive motor for frsh-air/recirculation valve...................................... 18 Removing and installing bulb for rotary blower switch..................................................... 19 Air conditioning.............................................................................................. 20 Safety regulations when handling refrigerant R 134a....................................................... 20 Assembly work on the air-conditioning system.............................................................. 21 Setpoints for pressures and temperatures.................................................................. 32 Removing and installing pressure switch for the air-conditioning system................................... 34 Removing and installing fluid tank........................................................................ 35 Removing and installing the compressor.................................................................... 36 Removing and installing the expansion valve............................................................... 39 Installing and removing the heating/air-conditioning unit................................................. 40 Removing and installing the condensor..................................................................... 44 Removing and installing the magnetic coupling............................................................. 45 Removing and installing drive motors of the heater/air-conditioning unit.................................. 47 Removing and installing drive motor for fresh-air/recirculation valve..................................... 49 Removing and installing outside temperature sensor........................................................ 50 Removing and installing inside temperature sensor......................................................... 51 Removing and installing footwell blower outlet sensor..................................................... 52 Removing and installing blower driver..................................................................... 53 Removing and installing fan for condenser................................................................. 54 Removing and installing ballast resistor for fan motor.................................................... 56 Removing and installing the heating/air-conditioning unit................................................. 57 Removing and installing compressor - GT3.................................................................. 59 Electrics......................................................................................................... 63 General....................................................................................................... 68 Work instructions after disconnecting the battery......................................................... 70 Instruments, alarm system..................................................................................... 74 Removing and installing instrument cluster................................................................ 74 Disassembling and assembling instrument cluster........................................................... 76 Removing and installing horn.............................................................................. 78 Setting ahead the total mileage counter in the instrument cluster......................................... 79 Coolant warning light in instrument cluster............................................................... 80 Radio, telephone, on-board computer, navigation............................................................... 81 Setting hands-free microphone to telephone type........................................................... 81 Removing and installing sensor for ParkAssistent.......................................................... 82 Removing and installing display and operator control unit (PCM)........................................... 85 Removing and installing navigation unit................................................................... 87 Removing and installing GPS antenna....................................................................... 88 Retrofitting mobile communication systems................................................................. 89 Adjusting (calibrating) PCM navigation unit............................................................... 91 Windshield wiper and washer system............................................................................ 93 Removing and installing wiper link........................................................................ 93 Removing and installing wiper blades...................................................................... 94 Removing and installing wiper motor....................................................................... 95 Removing and installing rear-window wiper system.......................................................... 96 Non-adjustable spray nozzles.............................................................................. 97 Removing and installing tank for windscreen washer system................................................. 98 Removing and installing pump for windscreen washer system................................................. 100 Removing and installing pump for headlight washing system................................................. 101 Removing and installing fluid level indicator............................................................. 102 Removing and installing spray nozzle for headlight washing system......................................... 103 Lights, lamps, switches exterior.............................................................................. 105 Removing and installing headlights........................................................................ 105 Headlights - basic adjustment in body..................................................................... 106 Removing and installing main light switch................................................................. 109 Removing and installing servo motor for headlight adjustment.............................................. 111 Removing and installing hazard warning light switch....................................................... 112 Masking film for left/right-hand traffic.................................................................. 113 Bulb overview and installation instructions............................................................... 115 Removing and installing halogen bulb...................................................................... 116 Removing and installing bulb for parking light............................................................ 117 Removing and installing bulb for fog light................................................................ 118 Removing and installing bulb for direction indicator light................................................ 119 Removing and installing bulb for side direction indicator light........................................... 120 Removing and installing bulb for tail light............................................................... 121 Removing and installing for number plate light............................................................ 122 Removing and installing bulb for raised brake light....................................................... 123 Removing and installing gas discharge lamp (Litronic headlights).......................................... 124 Removing and installing control module for gas discharge lamp............................................. 125 Removing and installing ignition unit for gas discharge lamp.............................................. 126 Removing and installing servo motor for automatic headlight beam adjustment............................... 127 Left / right traffic conversion for Litronic headlights................................................... 129 Troubleshooting on Litronic headlight (dipped beam)....................................................... 130 Removing and installing angle sensor for automatic headlight beam adjustment.............................. 131 Removing and installing angle sensor for automatic headlight beam adjustment.............................. 133 Removing and installing control module for automatic headlight beam adjustment............................ 134 Lights, lamps, switches interior, theft protection............................................................ 135 Removing and installing signal converter/immobiliser...................................................... 135 Removing and installing passenger compartment monitoring sensor........................................... 136 Additional alarm system M 534............................................................................. 137 Radio remote control in hand-held transmitter does not function........................................... 138 Bulb table and installation instructions.................................................................. 140 Removing and installing bulb for door warning light....................................................... 141 Removing and installing bulb for luggage compartment light................................................ 142 Removing and installing bulb for interior light........................................................... 143 Removing and installing bulb for instrument cluster....................................................... 144 Removing and installing bulb for engine compartment light................................................. 145 Teaching hand-held transmitter............................................................................ 146 Main switch for power supply - GT3........................................................................ 149 Disassembling and assembling hand-held transmitter........................................................ 150 Wiring Diagrams................................................................................................... 0 Wiring........................................................................................................ 5 Removing and installing current distributor............................................................... 6 Removing and installing fusible element in the current distributor........................................ 8 Allocation of free fuse connection points................................................................. 10 Measurement of closed-circuit current..................................................................... 11 Repair of main wiring harness............................................................................. 13 Repair of rear wiring harness............................................................................. 15 Wiring diagram for '98 model 911 Carrera (996)............................................................ 18 Wiring diagram for '99/'00 model 911 Carrera (996)........................................................ 90 Service Information Technik....................................................................................... 135 911 Targa..................................................................................................... 135 911 Carrera 4S................................................................................................ 181 All........................................................................................................... 192 Engine, Part 2 (as of Repair Group 15)................................................................................ 0 Engine - Cylinder head, valve drive............................................................................... 6 Diasassembling and assembling cylinder head - Inner parts..................................................... 8 Removing and installing valve springs......................................................................... 13 Removing and installing valve stem seal....................................................................... 15 Installing cylinder head...................................................................................... 16 Disassembling and assembling cylinder head - Camshaft drive................................................... 20 Removing and installing camshafts............................................................................. 27 Installing camshafts...................................................................................... 31 Adjusting timing - cylinder bank 1 - 3.................................................................... 42 Adjusting timing - cylinder bank 4 - 6.................................................................... 45 Removing and installing valve tappets - engine removed........................................................ 49 Removing valve tappets of cylinder bank 1 - 3............................................................. 52 Installing valve tappets - Cylinder bank 1 - 3............................................................ 55 Removing valve tappets of cylinder bank 4 - 6............................................................. 60 Installing valve tappets - Cylinder bank 4 - 6............................................................ 63 Completing camshafts.......................................................................................... 69 Sealing cover for camshaft housing (cylinder head cover)...................................................... 74 Checking guide for valve tappets.............................................................................. 77 Removing and installing oil protection tube (engine installed)................................................ 78 Removing and installing valve tappets (engine installed)...................................................... 83 Removing valve tappets of the cylinder bank 1 - 3 (engine installed)...................................... 87 Installing valve tappets of the cylinder bank 1 - 3 (engine installed).................................... 92 Adjusting timing of cylinder bank 1 - 3 (engine installed).................................................... 94 Removing valve tappets of the cylinder bank 4 - 6 (engine installed).......................................... 97 Installing valve tappets of the cylinder bank 4 - 6 (engine installed)........................................ 100 Adjusting timing of cylinder bank 4 - 6 (engine installed).................................................... 102 Removing and installing closure cap for camshaft bore (engine installed)...................................... 106 Checking camshaft (timing) (engine installed)................................................................. 110 Removing and installing sealing ring for intermidiate shaft (engine installed)................................ 117 Removing and installing solenoid hydraulic valve.............................................................. 122 Reworking cylinder head....................................................................................... 123 Removing and installing camshaft housing - GT3................................................................ 124 Removing camshaft housing - GT3........................................................................... 125 Installing camshaft housing - GT3......................................................................... 133 Removing and installing cylinder head - GT3................................................................... 145 Removing cylinder head - GT3.............................................................................. 146 Installing cylinder head - GT3............................................................................ 155 Disassembling and assembling intermediate shaft - GT3......................................................... 164 Engine - Lubrication.............................................................................................. 167 Removing and installing air/oil separator..................................................................... 167 Removing and installing oil pump with coolant guide housing................................................... 171 Removing and installing oil extraction pumps.................................................................. 179 Removing and installing oil extraction pump (engine installed)................................................ 181 Removing and installing oil-water heat exhanger - Engine installed............................................ 187 Removing and installing oil pan (engine installed)............................................................ 192 Removing and installing oil filler neck....................................................................... 195 Removing oil extraction pump - GT3............................................................................ 200 Disassembling and assembling oil extraction pump -GT3......................................................... 205 Installing oil extraction pump - GT3.......................................................................... 214 Removing and installing oil cooler - GT3...................................................................... 219 Removing and installing bracket for oil cooler - GT3.......................................................... 231 Removing bracket for oil cooler - GT3..................................................................... 232 Installing bracket for oil cooler - GT3................................................................... 245 Removing and Installing oil temperature sensor - GT3.......................................................... 258 Engine - Cooling.................................................................................................. 261 Draining and topping up with coolant.......................................................................... 261 Removing and installing coolant regulator..................................................................... 265 Removing and installing cooling pump.......................................................................... 268 Coolant warning light in instrument cluster................................................................... 276 Removing coolant pump (engine installed) - GT3................................................................ 277 Installing coolant pump (engine installed) - GT3.............................................................. 283 Removing and installing coolant regulator - GT3............................................................... 289 Removing and installing housing for coolant guide - GT3....................................................... 298 Removing housing for coolant guide - GT3.................................................................. 299 Installing housing for coolant guide - GT3................................................................ 311 Removing and installing temperature sensor for coolant - GT3.................................................. 323 Oil/coolant mixing............................................................................................ 325 Checking the cooling system for leaks......................................................................... 326 Removing and installing coolant hoses - GT3................................................................... 328 Removing coolant hoses.................................................................................... 329 Installing coolant hoses.................................................................................. 338 Tightening torques........................................................................................ 348 Fuel, exhaust, engine electronics..................................................................................... 0 Fuel supply, control.............................................................................................. 5 Checking fuel pressure........................................................................................ 6 Checking quantity delivered by fuel pump...................................................................... 8 Removing and installing fuel pump............................................................................. 9 Calibrating fuel level sensor system.......................................................................... 12 Removing and installing fuel filler neck...................................................................... 13 Removing and installing fuel tank............................................................................. 17 Calibrating fuel level sensor system - GT3.................................................................... 27 Fuel system, electronic injection................................................................................. 28 Disassembling and assembling fuel ring pipe................................................................... 28 Disassembling and assembling intake distributor............................................................... 31 Programming DME control module................................................................................ 36 Disassembling and assembling intake distributor - GT3......................................................... 39 Exhaust system.................................................................................................... 46 Removing and installing exhaust system - GT3.................................................................. 46 Removing exhaust system - GT3............................................................................. 47 Installing exhaust system - GT3........................................................................... 52 Removing and installing catalytic converters (engine installed)............................................... 57 Starter, power supply, cruise control............................................................................. 64 Removing and installing starter............................................................................... 64 Removing and installing three-phase generator................................................................. 66 Removing and installing cruise control actuator.............................................................. 68 Removing and installing starter - GT3......................................................................... 70 Removing and installing three-phase generator - GT3........................................................... 71 Removing and installing bracket for oil generator - GT3....................................................... 73 Work instructions after disconnecting the battery............................................................. 82 Ignition system................................................................................................... 86 Removing and installing ignition switch....................................................................... 86 Removing spark plugs - GT3.................................................................................... 88 Installing spark plugs - GT3.................................................................................. 89 Transmission, manual transmission..................................................................................... 0 911 Carrera (996)................................................................................................. 0 Transmission.................................................................................................. 10 Technical data............................................................................................ 11 6-Speed manual transmission G96/30.................................................................... 11 Manual transmission tightening torques............................................................ 13 Front wheel drive Z96.00.............................................................................. 14 Front-axle drive tightening torques................................................................... 18 Clutch, control............................................................................................... 19 Removing and installing clutch............................................................................ 19 Disassembling and assembling clutch....................................................................... 21 Bleeding the clutch system................................................................................ 23 Removing and installing clutch slave cylinder............................................................. 23 Removing and installing clutch pedal...................................................................... 25 Clutch boost spring: allocation and grease specification.................................................. 33 Removing and installing release bearing - GT3............................................................. 37 Manual transmission - Actuation, ass. housing................................................................. 43 Changing transmission oil................................................................................. 43 Removing and installing transmission G 96................................................................. 44 Removing and installing the shift console................................................................. 48 Removing and installing shift and selector cables........................................................ 52 Removing and installing closure cap for selector force mechanism.......................................... 0 Manual transmission - Gears, shafts, int. gearsh.............................................................. 72 Removing and installing sealing ring for input shaft...................................................... 59 Final drive - Differential, differential lock................................................................. 62 Removing and installing cover for final drive............................................................. 62 Removing and installing sealing ring for halfshaft flange of limited-slip differential.................... 64 Removing and installing sealing ring for halfshaft flange of differential................................. 65 911 Carrera 4 (996)............................................................................................... 71 Power Transmission............................................................................................ 72 Technical data............................................................................................ 73 Final drive - Differential, differential lock................................................................. 79 Removing and installing front final drive................................................................. 79 Removing and installing cardan shaft...................................................................... 83 Removing and installing sealing ring for cardan flange.................................................... 87 Removing and installing viscous clutch.................................................................... 91 Checking function of installed viscous clutch............................................................. 95 Removing and installing sealing ring for flanged shaft.................................................... 97 Removing and installing cover for final drive............................................................. 99 Changing oil for final drive.............................................................................. 102 Removing and installing support for final drive........................................................... 103 Repair........................................................................................................ 105 911 Carrera 4 (996)............................................................................................... 71 Power Transmission............................................................................................ 72 Technical data............................................................................................ 73 Final drive - Differential, differential lock................................................................. 79 Removing and installing front final drive................................................................. 79 Removing and installing cardan shaft...................................................................... 83 Removing and installing sealing ring for cardan flange.................................................... 87 Removing and installing viscous clutch.................................................................... 91 Checking function of installed viscous clutch............................................................. 95 Removing and installing sealing ring for flanged shaft.................................................... 97 Removing and installing cover for final drive............................................................. 99 Changing oil for final drive.............................................................................. 102 Removing and installing support for final drive........................................................... 103 911 Carrera (996) GT3............................................................................................. 105 Power Transmsiion............................................................................................. 106 Technical data (GT3)...................................................................................... 107 Manual transmission - Actuation, hausing...................................................................... 112 Removing and installing the transmission.................................................................. 112 Removing and installing closure cap for selector force mechanism.......................................... 116 Disassembling and assembling transmission................................................................. 119 Disassembling and assembling front transmission cover..................................................... 133 Disassembling and assembling gear housing................................................................ 135 Disassembling and assembling transmission housing......................................................... 139 Manual transmission - Gears, shafts, int. gearsh.............................................................. 146 Removing and installing sealing ring for input shaft...................................................... 146 Disassembling and assembling input shaft................................................................. 149 Removing and installing pinion shaft...................................................................... 154 Removing pinion shaft bearing............................................................................. 156 Final drive - Differential, differential lock................................................................. 157 Disassembling and assembling GKN differntial lock........................................................ 157 Removing and installing differential lock................................................................. 164 adjusting drive set....................................................................................... 166 Running gear.......................................................................................................... 0 911 Carrera (996)................................................................................................. 0 Running gear.................................................................................................. 6 Running gear - Overview: 911 Carrera (996)................................................................ 9 Stabaliser allocation..................................................................................... 12 Removing spring strut locking devices - Carrera and GT3................................................... 14 Running gear, general - GT3............................................................................... 15 Notes on repair instructions - GT3........................................................................ 16 Tests / notes - GT3....................................................................................... 18 Front wheel suspension, drive shafts.......................................................................... 20 Tightening torques for front axle......................................................................... 20 Removing and installing front spring strut................................................................ 24 Removing and installing front spring strut - GT3.......................................................... 26 Disassembling and assembling front spring strut........................................................... 31 Disassembling and assembling front spring strut - GT3..................................................... 37 Removing and installing front wheel bearing............................................................... 42 Installing caster eccentric............................................................................... 48 Rear wheel suspension, drive shafts........................................................................... 50 Tightening torques for rear axle.......................................................................... 50 Removing and installing rear spring strut................................................................ 53 Disassembling and assembling rear spring strut............................................................ 54 Disassembling and assembling rear spring strut - GT3...................................................... 62 Removing and installing rear wheel bearing................................................................ 68 Removing and installing rear tie rod (toe control arm).................................................... 74 Removing and installing rear wheel bearing housing (wheel carrier)........................................ 76 Removing and installing drive shaft (manual transmission)................................................. 83 Removing and installing drive shaft (Tiptronic transmission).............................................. 89 Wheels, tires, suspension alignment........................................................................... 95 Wheels and tyres (tyre pressure / mounting wheel on vehicle).............................................. 95 Adjustment values for suspension alignment................................................................ 97 Alignment cards for Carrera (996) and GT3................................................................. 100 Complete suspension alignment............................................................................. 101 Suspension alignment GT3.................................................................................. 102 General tyre mounting instructions........................................................................ 118 Checking rims............................................................................................. 122 Identifying size for 18-inch Turbo wheels (Technologie wheels)............................................ 123 Tyre failure/tyre sealant - GT3........................................................................... 124 Tyre mounting for critical wheels/tyre pairs.............................................................. 126 Anti-Lock Brake System (ABS).................................................................................. 131 Important information on ABS 5.3 and ABS/TC 5.3........................................................... 131 ABS 5.3 system description................................................................................ 132 ABS/TC 5.3 system description............................................................................. 134 Component arrangement (ABS and ABS/TC).................................................................... 136 Function of individual components......................................................................... 137 ABS test with Porsche System Tester 2..................................................................... 140 Removing and installing front speed sensor................................................................ 141 Removing and installing rear speed sensor................................................................. 142 Brakes - Brake mechanics...................................................................................... 143 Tightening torques for brake mechanics.................................................................... 143 Technical data (brake disc wear limit).................................................................... 144 Technical data (brake disc wear limit) - GT3.............................................................. 146 measuring brake pad thickness............................................................................. 148 Removing and installing front disc brake pads............................................................ 149 Removing and installing rear disc brake pads............................................................. 151 Adjusting brake push rod.................................................................................. 153 Checking brake-light switch setting....................................................................... 154 Adjusting parking brake shoes............................................................................. 156 Removing and installing front brake disc.................................................................. 158 Removing and installing rear brake disc................................................................... 160 Removing and installing parking brake shoes............................................................... 162 Measuring lateral runout of front brake discs............................................................. 165 Measuring lateral runout of rear brake discs.............................................................. 167 Removing and installing brake pedal...................................................................... 169 Brakes - Hydraulics, regulator, booster....................................................................... 179 Tightening torques for brake hydraulics................................................................... 179 Bleeding brakes........................................................................................... 180 Changing brake fluid...................................................................................... 183 Steering...................................................................................................... 184 Tightening torques for steering........................................................................... 184 Test and assembly work on power steering.................................................................. 185 Removing and installing steering wheel (airbag)........................................................... 186 Replacing steering system after accident damage........................................................... 188 Removing and installing steering gear..................................................................... 190 Plug couplings for steering hydraulics.................................................................... 194 Removing and installing lock barrel....................................................................... 199 Replacing steering lock................................................................................... 201 Removing and installing hydraulic pump.................................................................... 209 911 Carrera 4 (996)............................................................................................... 219 Running gear.................................................................................................. 220 Overview of 911 Carrera 4 running gear.................................................................... 221 Notes on repair instructions.............................................................................. 221 Tests/notes for all-wheel drive........................................................................... 222 Stabalizer allocation..................................................................................... 223 Anti-Lock Brake System (ABS).................................................................................. 238 Overview of PSM references................................................................................ 238 Calibrating steering angle sensor......................................................................... 240 PSM component arrangement................................................................................. 243 Brakes - Brake mechanics...................................................................................... 254 Technical data (brake disc wear dimension)................................................................ 254 Brakes - Hydraulics, regulator, booster....................................................................... 256 Bleeding brakes (vehicle with PSM)........................................................................ 256 Changing brake fluid (vehicle with PSM)................................................................... 259 Body.................................................................................................................. 0 Body - general.................................................................................................... 10 Safety instructions for body repair........................................................................... 14 Safety instructions for disassembling components.......................................................... 14 Safety instructions for air conditioning.................................................................. 14 Safety instructions for fuel tank......................................................................... 14 Safety instructions for for paintwork, glass, upholstery, linings......................................... 15 Safety instructions for airbag system..................................................................... 15 Safety instructions for door.............................................................................. 15 Safety instructions for sliding roof...................................................................... 17 Safety instructions for rear spoiler...................................................................... 17 Safety instructions for rear window....................................................................... 17 Safety instructions for windscreen........................................................................ 18 Safety instructions for heat shields...................................................................... 19 Safety instructions for cabriolet convertible top......................................................... 19 Safety instructions for roll-over protection system....................................................... 20 Safety instructions for plug location plan (body)......................................................... 20 Safety instructions for water drains (body)............................................................... 20 Safety instructions for welding........................................................................... 20 Safety instructions for Teromix-6700 two-component adhesive............................................... 21 Safety instructions for hydraulic system.................................................................. 21 Safety instructions for hardtop........................................................................... 21 Safety instructions for belt strap holder................................................................. 22 General information and quality notes......................................................................... 23 Electronic control modules................................................................................ 23 - Protection against overvoltage...................................................................... 23 - Replacing control modules........................................................................... 23 Tools and metalworking tools for body repairs................................................................. 24 Straightening systems..................................................................................... 24 Metalworking tools........................................................................................ 25 - Electrical equipment................................................................................ 25 - Mechanical equipment................................................................................ 25 - Compressed-air equipment............................................................................ 26 - Welding equipment................................................................................... 27 Check dimensions for body repair.............................................................................. 28 Floor assembly control dimensions for the 996 Carrera model up to model year 2000......................... 28 Floor assembly control dimensions for the the GT3 model................................................... 29 Floor assembly control dimensions for the 996 Carrera model from model year 2001.......................... 30 Body parts of high-strength steel............................................................................. 37 Water drainage plan........................................................................................... 43 Water drainage plan - Cabriolet............................................................................... 44 Check dimensions for body repair - Cabriolet structure........................................................ 45 Plug location plan............................................................................................ 48 Diagram - body gap dimensions................................................................................. 56 Diagram - keys to symbols for welding work.................................................................... 60 Resistance spot welding................................................................................... 60 Inert-gas arc welding (MAG procedure)..................................................................... 60 Gas welding............................................................................................... 60 Seam seals.................................................................................................... 61 Accessories............................................................................................... 62 - Front lid........................................................................................... 62 - Doors............................................................................................... 63 - Sliding roof panel.................................................................................. 63 - Rear lid............................................................................................ 64 Work sequence for accident repair............................................................................. 65 Body front........................................................................................................ 67 Removing and installing wheel housing liner................................................................... 67 Removing and installing the wing.............................................................................. 70 Replacing closing panel....................................................................................... 75 Cutting out closing panel and front floor panel........................................................... 76 Preparing closing panel and front floor panel for installation and fitting................................ 78 Welding in closing panel and front floor panel............................................................ 80 Tools and materials....................................................................................... 81 Replacing wheel housings and side members (sectional repair).................................................. 82 Cutting out wheel housings and side member................................................................ 83 Preparing wheel housings and side members for installation and fitting.................................... 85 Welding in wheel housing and side members................................................................. 87 Replacing wheel housings...................................................................................... 89 Removing wheel housing, lower shell and outer side member from the body................................... 90 Preparing wheel housing, lower shell and outer side member for installation and fitting................... 92 Welding wheel housing, lower shell and outer side members into the body................................... 94 Tools and materials....................................................................................... 95 Cleaning front water drains on Coupe and Cabriolet............................................................ 97 Replacing front wall.......................................................................................... 100 Cutting out front wall.................................................................................... 101 Preparing front wall for installation and fitting......................................................... 103 Welding in front wall..................................................................................... 105 Tools and materials....................................................................................... 106 Replacing front wall - Carrera 4 / GT 3....................................................................... 107 Cutting out front wall.................................................................................... 108 Preparing front wall for installation and fitting......................................................... 110 Welding in front wall..................................................................................... 112 Tools and materials....................................................................................... 113 Body centre, roof, frame.......................................................................................... 114 Removing and installing underbody cover....................................................................... 114 Repalcing rear centre panel................................................................................... 117 Removing and installing deformation element................................................................... 123 Replacing roof................................................................................................ 126 Disconnecting roof........................................................................................ 127 Preparation of roof for installation and fitting.......................................................... 129 Welding in roof........................................................................................... 131 Tools and materials....................................................................................... 132 Replacing lower side member................................................................................... 134 Cutting out lower side member............................................................................. 135 Preparation for installation of lower side member and fitting............................................. 137 Welding in lower side member.............................................................................. 139 Tools and materials....................................................................................... 140 Replacing lower side member - Cabriolet....................................................................... 141 Cutting out lower side member............................................................................. 142 Preparation for installation of lower side member and fitting............................................. 144 Welding lower side memeber................................................................................ 146 Tools and materials....................................................................................... 147 Replacing seat cross member................................................................................... 148 Cutting out seat cross member............................................................................. 149 Preparation of seat cross member for installation and fitting............................................. 151 Welding in seat cross member.............................................................................. 153 Tools and materials....................................................................................... 154 Body rear......................................................................................................... 155 Removing and installing wheel housing liner................................................................... 155 Cleaning rear water drains on Coupe and Cabriolet............................................................. 158 Replacing side section........................................................................................ 161 Replacing side section - Cabriolet............................................................................ 173 Replacing rear closing panel.................................................................................. 182 Replacing rear closing panel - GT 3........................................................................... 187 Cutting out rear closing panel............................................................................ 188 Preparing the rear closing panel for installation and fitting............................................. 190 Welding in rear closing panel............................................................................. 192 Tools and materials....................................................................................... 193 Lids.............................................................................................................. 195 Disassembling and assembling front lid........................................................................ 195 Disassembling and assembling rear lid......................................................................... 199 Disassembling and assembling release for front lid - up to model year 2000.................................... 205 Disassembling and assembling release for rear lid - up to model year 2000..................................... 210 Disassembling and assembling rear lid - GT3................................................................... 215 Disassembling and assembling release for front lid - as of model year 2001.................................... 221 Disassembling release for front lid....................................................................... 222 Assembling release for front lid.......................................................................... 224 Disassembling and assembling release for rear lid - from model year 2001..................................... 226 Disassembling release for rear lid........................................................................ 227 Assembling release for rear lid........................................................................... 229 Door front, central locking system................................................................................ 231 Removing and installing door.................................................................................. 231 Disassembling and assembling door............................................................................. 236 Disassembling door........................................................................................ 237 Assembling door........................................................................................... 242 Adjustment instructions for assembly of the door.............................................................. 248 Diagram: sheetmetal clips and grommets.................................................................... 248 Basic setting of door lock................................................................................ 248 - Basic setting of the door lock before installation.................................................. 249 Standardising the system.................................................................................. 249 - Standardising the power windows..................................................................... 249 - Blockage detection function......................................................................... 250 - Precondition for operation of the power windows..................................................... 250 Fitting the door window in the clamping jaws.............................................................. 250 Adjusting the door window angle in the vehicle's longitudinal direction................................... 251 Adjusting the door window height.......................................................................... 251 - Adjustment procedure:............................................................................... 251 - Checking the adjustment:............................................................................ 252 Adjustment of the door window pressing force on the door seal at the top and sides........................ 252 - Adjustment procedure:............................................................................... 228 Checking the adjustement:............................................................................. 252 Adjusting the lower stop of the power window unit......................................................... 253 Disassembling and assembling door handle...................................................................... 258 Setting the door.............................................................................................. 261 Removing and installing inner door release (bowden cable) for door lock....................................... 264 Removing and installing door handle........................................................................... 267 Removing and installing orientation lighting (LED light-emitting diodes)...................................... 270 Removing orientation lighting (LED light-emitting diodes)................................................. 270 Installing orientation lighting (LED light-emitting diodes)............................................... 272 Body equipment, exterior.............................................................................................. 0 Body equipment.................................................................................................... 10 Colour range for 1998 models.................................................................................. 13 Colour range for 1999 models.................................................................................. 14 Colour range for 2000 models.................................................................................. 16 Colour range for 2001 models.................................................................................. 17 Exterior paintwork solid.................................................................................. 17 Exterior paintwork metallic / pearl....................................................................... 17 Processing of Porsche 2-component window bonding agents....................................................... 18 Overview of tools and materials........................................................................... 18 Mixing procedure.......................................................................................... 19 Sliding roof...................................................................................................... 22 Removing and installing sliding roof panel.................................................................... 22 Removing and installing lifting/sliding roof drive............................................................ 30 Re-teaching the lifting/sliding roof drive.................................................................... 32 Removing and installing frame for sliding roof................................................................ 33 Disassembling and assembling frame for sliding roof........................................................... 38 Convertible top, hardtop.......................................................................................... 43 Removing and installing convertible top....................................................................... 43 Diagram of convertible top................................................................................ 44 Overview of convertible-top components.................................................................... 46 Removing convertible top.................................................................................. 48 Installing convertible top................................................................................ 52 Removing and installing water collection tray................................................................. 56 Removing and installing convertible-top compartment lid....................................................... 60 Replacing convertible-top covering............................................................................ 66 Adjusting Cabriolet convertible top........................................................................... 84 Convertible top repair - after emergency operation............................................................ 88 Removing and installing rear side section flap................................................................ 95 Removing and installing hydraulic cylinders................................................................... 100 Removing and installing convertible-top control module........................................................ 105 Removing and installing convertible-top compartment lid drive................................................. 107 Removing and installing hardtop............................................................................... 108 Disassembling and assembling hardtop.......................................................................... 114 Replacing convertible-top frame............................................................................... 136 Removing and installing micro switch for convertible-top compartment lid...................................... 151 Removing and installing micro switch for rear side section flap............................................... 152 Removing and installing additional flap....................................................................... 154 Assembly instructions for hardtop assembly fixture............................................................ 157 Converting hinge from convertible-top compartment lid (Cabriolet)............................................. 163 Removing and installing potentiometer for convertible-top interrogation....................................... 165 Removing and installing motor for rear side section flap..................................................... 167 Calibrating convertible top................................................................................... 168 Adjusting the hardtop......................................................................................... 169 Care and cleaning of the convertible top...................................................................... 174 Cleaning the convertible top.............................................................................. 174 Care of convertible top................................................................................... 175 Care of convertible-top seals............................................................................. 176 Bumpers........................................................................................................... 177 Removing and installing front spoiler......................................................................... 177 Removing and installing rear spoiler.......................................................................... 183 Removing and installing front spoiler - GT 3.................................................................. 190 Glazing, window control........................................................................................... 195 Removing and installing windscreen............................................................................ 195 Removing the windscreen................................................................................... 196 Fitting the windscreen.................................................................................... 199 Overview of tools and materials........................................................................... 202 Removing and installing side window........................................................................... 204 Removing and installing rear window........................................................................... 209 Removing and installing rear window (hardtop)................................................................. 217 Removing and installing flexible rear window of Cabriolet..................................................... 225 Removing and installing rear power windows (Cabriolet)........................................................ 232 Removing and installing rear side window (Cabriolet).......................................................... 239 Removing and installing rear side window seal (Cabriolet)..................................................... 241 Removing and installing power window motor.................................................................... 242 Checking function of heating for rear window.................................................................. 244 Exterior equipment................................................................................................ 245 Disassembling and assembling the rearview mirror.............................................................. 245 Removing and installing roof joint strip...................................................................... 248 Removing and installing sill cover - GT 3..................................................................... 253 Checking function of heating for mirror glass................................................................. 262 Interior equipment................................................................................................ 263 Removing and installing the interior rearview mirror.......................................................... 263 Bonding the interior rearview mirror.......................................................................... 266 Removing and installing centre console........................................................................ 270 Removing and installing sun visors............................................................................ 274 Disassembling and assembling sun visors....................................................................... 277 Removing and installing inner sill (driver's side) - as of model year 2001.................................... 282 Disassembling release for front lid....................................................................... 283 Assembling release for front lid.......................................................................... 285 Removing and installing inner sill (passenger's side)......................................................... 287 Removing inner sill....................................................................................... 288 Installing inner sill..................................................................................... 290 Passenger protection.............................................................................................. 292 Safety regulations for airbag vehicles........................................................................ 292 Disposal of airbag units...................................................................................... 296 Removing and installing the driver's airbag unit.............................................................. 301 Removing and installing the contact unit...................................................................... 302 Removing and installing the triggering unit for the airbag.................................................... 303 Removing and installing the passenger's airbag unit........................................................... 304 Removing and installing the side airbag unit.................................................................. 306 Removing and installing roll-over bar......................................................................... 308 Removing and installing frame for roll-over protection system................................................. 315 Removing and installing control module for roll-over protection system........................................ 319 Removing and installing roll-over bar - GT 3 - up to model year 2000.......................................... 320 Removing and installing roll-over bar - GT 3 - up to model year 2001.......................................... 329 Removing roll-over bar.................................................................................... 330 Adjusting roll-over bar................................................................................... 338 Assembly instructions for the rear trim, the floor covering and the closure caps.......................... 340 Body equipment, interior.............................................................................................. 0 Body equipment, interior.......................................................................................... 0 Special notes for the care of soft-lock paint surfaces........................................................ 12 Light soiling (e.g. dust)................................................................................. 12 Heavy soiling (e.g. oily, greasy dirt).................................................................... 12 Linings, insulation............................................................................................... 14 Disassembling and assembling the dashboard.................................................................... 14 Disassembling the dashboard............................................................................... 15 - Removing the regulator for wiping interval.......................................................... 21 - Removing the cigarette lighter...................................................................... 21 Assembling the dashboard.................................................................................. 22 - Installing the regulator for wiping interval........................................................ 28 - Instaling the cigarette lighter..................................................................... 28 Removing and installing the dashboard......................................................................... 29 Removing and installing door trim panel....................................................................... 33 Remove door trim panel.................................................................................... 34 Install door trim panel................................................................................... 36 Additional assembly notes on bowden cable variant A and inner door handle................................. 37 - Up to Veh. Ident. Nos. Bowden cable variant A....................................................... 38 - Up to Veh. Ident. Nos. Inner door handle variant A.................................................. 38 - Removal and installation of bowden cable variant A.................................................. 38 Assembly note on door film for vehicles without side airbag............................................... 39 Fitting sliding strip on the inner door panel............................................................. 39 Removing and installing oddments compartment lid.............................................................. 41 Removing and installing oddments compartment lid.......................................................... 41 Removing and installing cowl panel cover...................................................................... 44 Removing and installing roof lining - cabriolet............................................................... 48 Removing and installing side-panel lining..................................................................... 57 Removing side-panel lining................................................................................ 58 Installing side-panel lining.............................................................................. 60 Removing and installing trim of A, B and C-pillars............................................................ 67 Removing and installing trim of A, B and C-pillars........................................................ 68 Installing trim of A, B and C-pillars..................................................................... 70 Removing and installing roof lining........................................................................... 72 Seat frames....................................................................................................... 79 Removing and installing front seat............................................................................ 79 Removing front seat....................................................................................... 80 Installing front seat..................................................................................... 82 Removing and installing bucket seat - GT3..................................................................... 84 Air conditioning...................................................................................................... 0 Air conditioning.................................................................................................. 5 Technical data for the air conditioning system................................................................ 6 Heating........................................................................................................... 7 Removing and installing heat exchanger........................................................................ 7 Ventilation....................................................................................................... 8 Removing and installing mechanical heating / fresh air control................................................ 8 Removing and installing heating / fresh air unit.............................................................. 9 Installing and adjusting bowden cables of the heating/fresh-air control....................................... 13 Removing and installing heater/fresh-air blower motor......................................................... 16 Removing and installing drive motor for frsh-air/recirculation valve.......................................... 18 Removing and installing bulb for rotary blower switch......................................................... 19 Air conditioning.................................................................................................. 20 Safety regulations when handling refrigerant R 134a........................................................... 20 Assembly work on the air-conditioning system.................................................................. 21 Setpoints for pressures and temperatures...................................................................... 32 Removing and installing pressure switch for the air-conditioning system....................................... 34 Removing and installing fluid tank............................................................................ 35 Removing and installing the compressor........................................................................ 36 Removing and installing the expansion valve................................................................... 39 Installing and removing the heating/air-conditioning unit..................................................... 40 Removing and installing the condensor......................................................................... 44 Removing and installing the magnetic coupling................................................................. 45 Removing and installing drive motors of the heater/air-conditioning unit...................................... 47 Removing and installing drive motor for fresh-air/recirculation valve......................................... 49 Removing and installing outside temperature sensor............................................................ 50 Removing and installing inside temperature sensor............................................................. 51 Removing and installing footwell blower outlet sensor......................................................... 52 Removing and installing blower driver......................................................................... 53 Removing and installing fan for condenser..................................................................... 54 Removing and installing ballast resistor for fan motor........................................................ 56 Removing and installing the heating/air-conditioning unit..................................................... 57 Removing and installing compressor - GT3...................................................................... 59 Electrics............................................................................................................. 63 General........................................................................................................... 68 Work instructions after disconnecting the battery............................................................. 70 Instruments, alarm system......................................................................................... 74 Removing and installing instrument cluster.................................................................... 74 Disassembling and assembling instrument cluster............................................................... 76 Removing and installing horn.................................................................................. 78 Setting ahead the total mileage counter in the instrument cluster............................................. 79 Coolant warning light in instrument cluster................................................................... 80 Radio, telephone, on-board computer, navigation................................................................... 81 Setting hands-free microphone to telephone type............................................................... 81 Removing and installing sensor for ParkAssistent.............................................................. 82 Removing and installing display and operator control unit (PCM)............................................... 85 Removing and installing navigation unit....................................................................... 87 Removing and installing GPS antenna........................................................................... 88 Retrofitting mobile communication systems..................................................................... 89 Adjusting (calibrating) PCM navigation unit................................................................... 91 Windshield wiper and washer system................................................................................ 93 Removing and installing wiper link............................................................................ 93 Removing and installing wiper blades.......................................................................... 94 Removing and installing wiper motor........................................................................... 95 Removing and installing rear-window wiper system.............................................................. 96 Non-adjustable spray nozzles.................................................................................. 97 Removing and installing tank for windscreen washer system..................................................... 98 Removing and installing pump for windscreen washer system..................................................... 100 Removing and installing pump for headlight washing system..................................................... 101 Removing and installing fluid level indicator................................................................. 102 Removing and installing spray nozzle for headlight washing system............................................. 103 Lights, lamps, switches exterior.................................................................................. 105 Removing and installing headlights............................................................................ 105 Headlights - basic adjustment in body......................................................................... 106 Removing and installing main light switch..................................................................... 109 Removing and installing servo motor for headlight adjustment.................................................. 111 Removing and installing hazard warning light switch........................................................... 112 Masking film for left/right-hand traffic...................................................................... 113 Bulb overview and installation instructions................................................................... 115 Removing and installing halogen bulb.......................................................................... 116 Removing and installing bulb for parking light................................................................ 117 Removing and installing bulb for fog light.................................................................... 118 Removing and installing bulb for direction indicator light.................................................... 119 Removing and installing bulb for side direction indicator light............................................... 120 Removing and installing bulb for tail light................................................................... 121 Removing and installing for number plate light................................................................ 122 Removing and installing bulb for raised brake light........................................................... 123 Removing and installing gas discharge lamp (Litronic headlights).............................................. 124 Removing and installing control module for gas discharge lamp................................................. 125 Removing and installing ignition unit for gas discharge lamp.................................................. 126 Removing and installing servo motor for automatic headlight beam adjustment................................... 127 Left / right traffic conversion for Litronic headlights....................................................... 129 Troubleshooting on Litronic headlight (dipped beam)........................................................... 130 Removing and installing angle sensor for automatic headlight beam adjustment.................................. 131 Removing and installing angle sensor for automatic headlight beam adjustment.................................. 133 Removing and installing control module for automatic headlight beam adjustment................................ 134 Lights, lamps, switches interior, theft protection................................................................ 135 Removing and installing signal converter/immobiliser.......................................................... 135 Removing and installing passenger compartment monitoring sensor............................................... 136 Additional alarm system M 534................................................................................. 137 Radio remote control in hand-held transmitter does not function............................................... 138 Bulb table and installation instructions...................................................................... 140 Removing and installing bulb for door warning light........................................................... 141 Removing and installing bulb for luggage compartment light.................................................... 142 Removing and installing bulb for interior light............................................................... 143 Removing and installing bulb for instrument cluster........................................................... 144 Removing and installing bulb for engine compartment light..................................................... 145 Teaching hand-held transmitter................................................................................ 146 Main switch for power supply - GT3............................................................................ 149 Disassembling and assembling hand-held transmitter............................................................ 150 911 Carrera (996) Model 99/00.........................................................................................2313 Table of Contents.................................................................................................2314 Wiring Diagram....................................................................................................2315 Sheet 1 - Lights Row..............................................................................................2316 Sheet 2 - Lights USA / Canada.....................................................................................2317 Sheet 3 - Instrument Cluster and Sensor...........................................................................2318 Sheet 4 - Wipe and Wash Cleaners, Two-Tone Horns, Power Window....................................................2319 Sheet 5 - Engine Cooling, Heater, Air Conditioning System.........................................................2320 Sheet 6 - Mirror Adjustment, Seat Heating, Rear Window Defogger...................................................2321 Sheet 7 - Sun Roof, Convertible Top Drive, Sensor Overturn........................................................2322 Sheet 8 - Spoiler Extend, Parking Assistant.......................................................................2323 Sheet 9 - Central Locking System, Alarm System, Interior Monitoring, Radio Remote Control, Anti-Drive-Off Lock....2324 Sheet 10 - ABS....................................................................................................2325 Sheet 11 - Tiptronic..............................................................................................2326 Sheet 12 - DME 5.2 Engine, Fuel, Ignition System..................................................................2327 Sheet 13 - Cruise Control, Airbag.................................................................................2328 Sheet 14 - Radio, Telephone.......................................................................................2329 Sheet 14A - PCM - Infosystem, Navigation..........................................................................2330 Sheet 15 - Memory Seat and Mirror.................................................................................2331 Sheet 16 - Power Supply...........................................................................................2332 Sheet 17 - Ground Points..........................................................................................2333 Sheet 18 - ME 7 Motronic / E-Gas (Engine).........................................................................2334 Sheet 19 - ME 7 Motronic / E-Gas (Body)...........................................................................2335 Sheet 20 - PSM - Porsche Stability Management.....................................................................2336 Sheet 21 - Construction Components................................................................................2337 Sheet 22 - Connectors and Abbrevations............................................................................2338 Sheet 23 - Welding Point..........................................................................................2339 Sheet 24 - Relay Support 1, Relay Support 2.......................................................................2340 Sheet 25 - Fuses..................................................................................................2341 Sheet 26 - Additional Wiring Diagram..............................................................................2342
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