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2001-2005 Porsche 911 Turbo (996) GT2 Technical Manual – PDF DOWNLOAD
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2001-2005 Porsche 911 Turbo (996) GT2 Technical Manual – PDF DOWNLOAD
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Description
2001-2005 Porsche 911 Turbo (996) GT2 Technical Manual – PDF DOWNLOAD
FILE DETAILS:
2001-2005 Porsche 911 Turbo (996) GT2 Technical Manual – PDF DOWNLOAD
Language : English
Pages : 2099
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
2001-2005 Porsche 911 Turbo (996) GT2 Technical Manual – PDF DOWNLOAD
General preconditions for repairing Porsche vehicles:
- The descriptions form the basis for professional and correct maintenance and repair work. The content of the
work procedures described is based on the level of training of a fitter with a sound knowledge of the product. - The fitter must have obtained knowledge of the product at training programs and courses offered by the Dr.
Ing. h.c.F. Porsche AG which are specific to the product and assembly before carrying out any of the work. - This level of knowledge is the precondition for carrying out the work described. The Dr. Ing. h.c. F. Porsche
AG will not be held liable if the described repair work is carried out without this knowledge.
Preconditions for body work on Porsche vehicles:
The described repair work only applies to standard cases. Body repairs must only be carried out by skilled
persons who are specialised for such work. Given the overall picture of the damages, the workshop itself must
decide whether it is possible to return the vehicle to its proper condition. Repair works on Porsche vehicles
must be carried out with the tools and workshop equipment recommended and approved by the Dr. Ing. h.c. F.
Porsche AG. All body repair work must be carried out correctly and according to the Dr. Ing. h.c. F. Porsche
AG instructions for sheetmetal, paint and corrosion protection/preservation work.
TABLE OF CONTENTS:
2001-2005 Porsche 911 Turbo (996) GT2 Technical Manual – PDF DOWNLOAD
911 Turbo (996) TECHNICAL MANUAL...................................................................................................1843 General........................................................................................................................1843 Structure......................................................................................................................1843 Breakdown of Repair Groups.....................................................................................................1843 Legend for structure of sequence description...................................................................................1843 Structure of exploded view.....................................................................................................1845 Structure of sequence description..............................................................................................1846 Preconditions for using workshop documentation for Porsche vehicles................................................................1858 Information on handling of the GT2 scope........................................................................................... 64 TABLE OF CONTENTS.................................................................................................................. 2 GROUP 0 GENERAL.................................................................................................................... 0 0 TECHNICAL.................................................................................................................... 0 0 Technical data........................................................................................................... 65 Engine................................................................................................................. 66 Engine design.......................................................................................................... 67 Engine cooling......................................................................................................... 68 Engine lubrication..................................................................................................... 68 Engine control......................................................................................................... 68 Heating................................................................................................................ 69 Fuel system............................................................................................................ 69 Electrical system...................................................................................................... 69 Exhaust system......................................................................................................... 70 Emission control....................................................................................................... 70 Transmission........................................................................................................... 70 Clutch................................................................................................................. 70 Transmission........................................................................................................... 71 Body designs........................................................................................................... 72 Running gear........................................................................................................... 72 Brakes................................................................................................................. 73 Wheels and tyres....................................................................................................... 74 Spare wheel............................................................................................................ 74 Wheel alignment........................................................................................................ 74 Dimensions............................................................................................................. 75 Weights according to DIN 700 20........................................................................................ 75 Filling capacities..................................................................................................... 76 Performance data....................................................................................................... 77 Climbing performance................................................................................................... 78 Specific power......................................................................................................... 78 0 Entire vehicle General................................................................................................. 79 Lifting the vehicle.................................................................................................... 79 0 Power unit............................................................................................................... 80 Engine M96/70.......................................................................................................... 80 Engine................................................................................................................. 81 Engine design.......................................................................................................... 81 Engine cooling......................................................................................................... 82 Engine lubrication..................................................................................................... 82 Engine control......................................................................................................... 83 0 Transmission............................................................................................................. 84 6-speed manual transmission G 96.50.................................................................................... 84 Front wheel drive Z 96.00.............................................................................................. 85 0 Body..................................................................................................................... 86 Body of high-strength steel 1.......................................................................................... 86 Body of high-strength steel 2.......................................................................................... 87 Water drainage plan Coupé............................................................................................ 88 Refrigerant circuit.................................................................................................... 89 Component arrangement, Airbag System B05............................................................................... 89 0 Electrics................................................................................................................ 91 Fuse assignments....................................................................................................... 91 0 Power supply............................................................................................................. 94 Work instructions after disconnecting the battery...................................................................... 94 Control module memories................................................................................................ 94 Supply voltage fault entry............................................................................................. 95 Test drive after connecting the battery................................................................................ 95 2470 DME control module................................................................................................ 95 3730 Tiptronic......................................................................................................... 96 6452 Power windows..................................................................................................... 96 90 25 Instrument cluster............................................................................................... 96 9030 Clock............................................................................................................. 96 9023 Fuel level display................................................................................................ 97 9120 Radio............................................................................................................. 97 9110 PCM............................................................................................................... 97 01 SALES CHECK................................................................................................................. 0 01 Sales check............................................................................................................. 440 01 General maintenance: Test drive......................................................................................... 99 01 Diagnostic system: Read out fault memory and activate systems........................................................... 100 Activating systems..................................................................................................... 100 Read out fault memory.................................................................................................. 100 Load Navigation........................................................................................................ 101 01 Battery: checking the charge state...................................................................................... 102 Tools.................................................................................................................. 102 Checking charge state with battery tester.............................................................................. 102 01 Windscreen wiper/washer system, headlight washer........................................................................ 103 Mix ratio of fluids for windscreen washer system....................................................................... 103 01 Checking the function of the vehicle's lights and the headlight setting................................................. 104 Checking the adjustment of the headlights.............................................................................. 104 Adjusting the main headlights.......................................................................................... 105 Adjusting the main headlights, USA version............................................................................. 106 Fog light adjustment................................................................................................... 106 01 Checking the function of electrical equipment, as well as the indicator and warning lights.............................. 108 01 Alarm system: checking operation of indicators.......................................................................... 109 01 Activating/deactivating the parking aid................................................................................. 110 General................................................................................................................ 110 Activating the parking aid without PST 2............................................................................... 110 Deactivating the parking aid without PST 2............................................................................. 111 Activating the parking aid with PST 2.................................................................................. 111 Selecting door mirror to be lowered, left/right........................................................................ 112 Adjusting the lowering angle for the passenger door mirror............................................................. 112 Deactivating the parking aid with PST 2................................................................................ 113 01 Removing transport lock (spring strut locking devices) Turbo and GT2.................................................. 114 General................................................................................................................ 114 Removing spring strut locking devices.................................................................................. 114 01 Mobile roofs: checking function.........................................................................................1860 Checking sliding roof..................................................................................................1860 Checking convertible top...............................................................................................1860 Checking the hardtop...................................................................................................1860 01 Glazing: visual inspection for damage...................................................................................1862 01 Checking lid and doors..................................................................................................1863 Checking lid lock, front and rear......................................................................................1863 Checking safety hook, front lid........................................................................................1863 Function test, checking door lock......................................................................................1863 Functional inspection of the tank cap lock.............................................................................1863 01 Interior equipment: visual inspection for damage and soiling............................................................1864 01 Removing transport protection...........................................................................................1865 1 Removing external transport protection...............................................................................1865 1 Removing internal transport protection...............................................................................1866 01 Installing air guides for PCCB brake discs - GT2........................................................................1867 Installing front air guides............................................................................................1867 Installing rear air guides.............................................................................................1867 01 Fitting front lip GT2.................................................................................................1869 01 Fitting six-point seat belt GT2.......................................................................................1870 01 Checking the Vehicle Ident. No..........................................................................................1872 01 Checking the exterior equipment and paint finish........................................................................1873 Checking exterior equipment............................................................................................1873 Checking paint finish..................................................................................................1873 01 Completing vehicle and checking equipment for completeness..............................................................1874 Checking vehicle equipment for completeness............................................................................1874 Tools..............................................................................................................1874 Completing the vehicle.................................................................................................1875 03 MAINTENANCE................................................................................................................. 0 03 Diagnostic system: reading out fault memory............................................................................. 125 Reading out fault memory............................................................................................... 125 03 General maintenance: test drive......................................................................................... 126 03 Removing and installing drive belt...................................................................................... 127 Removal overview of the drive belt (engine installed).................................................................. 127 Installation overview of the drive belt (engine installed)............................................................. 128 03 Changing the engine oil and oil filter.................................................................................. 131 03 Changing the engine oil (without oil filter)............................................................................ 135 03 Replacing spark plugs................................................................................................... 137 Removing spark plugs................................................................................................... 137 Installing spark plugs................................................................................................. 138 03 Checking cooling system................................................................................................. 140 Coolant: checking level, antifreeze content and leaks.................................................................. 140 03 Replacing air cleaner element........................................................................................... 142 Removing air cleaner................................................................................................... 142 Installing air cleaner................................................................................................. 144 03 Replacing the fuel filter............................................................................................... 148 03 Clutch: checking the play and pedal end position........................................................................ 152 Checking clutch free play.............................................................................................. 152 Checking the pedal end position (pedal return/return force)............................................................ 152 03 Changing transmission oil............................................................................................... 153 Changing transmission oil.............................................................................................. 153 Tightening torques..................................................................................................... 153 03 Changing transmission oil - GT2......................................................................................... 168 Changing transmission oil - GT2........................................................................................ 168 Topping up transmission oil - GT2...................................................................................... 168 Tightening torques..................................................................................................... 169 03 Checking and topping up the ATF......................................................................................... 154 Tools.................................................................................................................. 154 Checking and topping up the ATF........................................................................................ 154 Tightening torques..................................................................................................... 156 03 Replacing ATF........................................................................................................... 157 Tools.................................................................................................................. 157 Replacing ATF fluid.................................................................................................... 157 Tightening torques..................................................................................................... 159 03 Removing and installing ATF filter...................................................................................... 160 Tools.................................................................................................................. 160 Removing ATF filter.................................................................................................... 160 Installing ATF filter.................................................................................................. 161 Tightening torques..................................................................................................... 162 03 Replacing and checking transmission oil in final drive.................................................................. 163 Tools.................................................................................................................. 163 Changing transmission oil in final drive............................................................................... 163 Tightening torques..................................................................................................... 165 03 Changing transmission oil in front wheel drive.......................................................................... 166 Changing transmission oil in front wheel drive......................................................................... 166 Tightening torques..................................................................................................... 166 03 Steering gear: fluid level and bellows.................................................................................. 170 Power steering: checking the fluid level............................................................................... 170 General............................................................................................................ 170 Power steering: checking the fluid level........................................................................... 170 Steering gear: visual inspection of the bellows........................................................................ 172 03 Axle joints/drive shafts................................................................................................ 173 Tie rod ends: checking the play and dust bellows....................................................................... 173 Axle joints: checking the play and dust bellows........................................................................ 173 Drive shafts: visual inspection of the boots........................................................................... 174 03 Running gear adjustment/storage of assemblies........................................................................... 175 Running gear adjustment (wheel alignment values)....................................................................... 175 Storage of assemblies and running gear................................................................................. 175 03 Tyres and spare wheel: checking condition and tyre pressure............................................................. 176 Checking condition..................................................................................................... 176 Tyre pressure for cold tyres (approx. 20 °C)........................................................................... 176 911 Turbo.......................................................................................................... 176 911 GT2 (M002/M003)................................................................................................ 176 03 Checking and changing the brake fluid................................................................................... 178 Checking the brake fluid level......................................................................................... 178 Changing the brake fluid............................................................................................... 178 03 Parking brake: checking the free play of the parking brake lever........................................................ 180 Parking brake: checking the free play of the parking brake lever....................................................... 180 Adjusting the parking brake........................................................................................ 180 03 Visual inspection: brake lines/brake pads/brake discs................................................................... 182 Brake hoses and lines.................................................................................................. 182 Brake system: visual inspection of the brake pads and brake discs for wear............................................. 182 03 Checking the wheel mounting............................................................................................. 184 03 Checking lid and doors.................................................................................................. 185 Checking lid lock, front and rear...................................................................................... 185 Checking the catch bar............................................................................................. 185 Checking safety hook, front lid........................................................................................ 185 Function test, checking door lock...................................................................................... 185 Functional inspection of the tank cap lock............................................................................. 186 Checking door and lid tightening torques............................................................................... 186 Checking inner release of luggage compartment (Trunk Entrapment)....................................................... 186 Tightening torques..................................................................................................... 187 03 Checking seat belts..................................................................................................... 188 Functional inspection.................................................................................................. 188 Condition inspection................................................................................................... 188 03 Inspecting the airbag system............................................................................................ 189 Visual inspection...................................................................................................... 189 Checking airbag warning light.......................................................................................... 189 Function test of the airbag system..................................................................................... 189 03 Passenger protection maintenance: checking roll-over protection system.................................................. 191 03 Particle filter: replacing the filter element........................................................................... 192 Removing particle filter............................................................................................... 192 Installing particle filter............................................................................................. 192 03 Checking the function of the vehicle's lights........................................................................... 193 Adjusting the main headlights.......................................................................................... 193 Setting................................................................................................................ 194 Adjusting the main headlights, USA version............................................................................. 195 Fog light adjustment................................................................................................... 195 Removing main headlight................................................................................................ 195 Installing main headlight.............................................................................................. 196 03 Windscreen wiper/washer system, headlight washer........................................................................ 198 03 Checking the function of electrical equipment, as well as the indicator and warning lights.............................. 199 03 Additional maintenance - USA............................................................................................ 200 Additional maintenance, replacing spark plugs.......................................................................... 200 Additional maintenance every 60,000 mls/96,000 km...................................................................... 200 Additional maintenance every 90,000 mls/144,000 km..................................................................... 201 Maintenance every 2 years.............................................................................................. 201 Maintenance after 4, 8, 10 then every 2 years.......................................................................... 201 03 Additional maintenance - as of MY 2004.................................................................................. 202 Additional maintenance, replacing spark plugs.......................................................................... 202 Additional maintenance every 80,000 km/48,000 mls...................................................................... 202 Additional maintenance every 160,000 km/96,000 mls..................................................................... 202 Maintenance every 2 years.............................................................................................. 203 Maintenance after 4, 8, 10 then every 2 years.......................................................................... 203 03 Additional maintenance - USA - as of MY 2004............................................................................ 204 Additional maintenance, replacing spark plugs.......................................................................... 204 Additional maintenance every 60,000 mls/96,000 km...................................................................... 204 Additional maintenance every 90,000 mls/144,000 km..................................................................... 205 Maintenance every 2 years.............................................................................................. 205 Maintenance after 4, 8, 10 then every 2 years.......................................................................... 205 03 Additional maintenance.................................................................................................. 207 Additional maintenance, replacing spark plugs.......................................................................... 207 Additional maintenance every 80,000 km/48,000 mls...................................................................... 207 Additional maintenance every 160,000 km/96,000 mls..................................................................... 207 Maintenance every 2 years.............................................................................................. 208 Maintenance after 4, 8, 10 then every 2 years.......................................................................... 208 03 24 00 Minor maintenance................................................................................................. 442 03 24 00 Minor maintenance - USA........................................................................................... 749 03 24 00 Minor maintenance - as of MY 2003................................................................................. 751 03 24 00 Minor maintenance - USA - as of MY 2003........................................................................... 753 03 24 00 Minor maintenance - as of MY 2004................................................................................. 755 03 24 00 Minor maintenance - USA - as of MY 2004........................................................................... 757 03 26 00 Major maintenance................................................................................................. 444 03 26 00 Major maintenance - USA........................................................................................... 763 03 26 00 Major maintenance - as of MY 2003................................................................................. 765 03 26 00 Major maintenance - USA - as of MY 2003........................................................................... 767 03 26 00 Major maintenance - as of MY 2004................................................................................. 769 03 26 00 Major maintenance - USA - as of MY 2004........................................................................... 771 03 50 00 Annual maintenance................................................................................................ 446 03 50 00 Annual maintenance - USA.......................................................................................... 790 03 50 00 Annual maintenance - as of MY 2004................................................................................ 792 03 50 00 Annual maintenance - USA - as of MY 2004.......................................................................... 793 GROUP 1 ENGINE..................................................................................................................... 0 1 TECHNICAL DATA............................................................................................................... 0 1 Technical data........................................................................................................... 120 Engine................................................................................................................. 121 Engine design.......................................................................................................... 121 Engine cooling......................................................................................................... 122 Engine lubrication..................................................................................................... 122 Engine control......................................................................................................... 122 Fuel system............................................................................................................ 123 Electrical system...................................................................................................... 123 Exhaust system......................................................................................................... 123 Emission control....................................................................................................... 123 1 Technical Data GT2..................................................................................................... 116 Engine................................................................................................................. 117 Engine design.......................................................................................................... 117 Engine cooling......................................................................................................... 118 Engine lubrication..................................................................................................... 118 Engine control......................................................................................................... 118 Fuel system............................................................................................................ 119 Electrical system...................................................................................................... 119 Exhaust system......................................................................................................... 119 Emission control....................................................................................................... 119 10 CRANKCASE, SUSPENSION....................................................................................................... 0 10 01 00 Tightening torques for M 96/70 engine............................................................................. 448 Crankshaft/crankcase................................................................................................... 448 Cylinder, cylinder head and camshaft housing........................................................................... 448 10 01 19 Removing and installing engine-Removing...........................................................................1231 Tools for removal......................................................................................................1231 Removing engine........................................................................................................1232 10 01 19 Removing and installing engine-Installing.........................................................................1242 Installing engine......................................................................................................1242 Tightening torques: Removing and installing engine.....................................................................1245 10 10 37 Disassembling and assembling crankcase............................................................................ 450 Tools.................................................................................................................. 450 Adapting engine holder................................................................................................. 453 Left crankcase half (cylinder bank 1 3).............................................................................. 455 Right crankcase half (cylinder bank 4 - 6)............................................................................. 457 Disassembling the crankcase............................................................................................ 459 Assembling the crankcase............................................................................................... 462 13 CRANKSHAFT, PISTONS......................................................................................................... 0 13 10 19 Removing and installing pistons (includes removing and installing cylinders)...................................... 474 Tools.................................................................................................................. 474 Removing pistons and cylinders......................................................................................... 475 Removing pistons....................................................................................................... 477 Installing pistons and cylinders....................................................................................... 478 13 19 21 Removing piston rings............................................................................................. 486 Tools.................................................................................................................. 486 Removal................................................................................................................ 486 13 19 23 Installing piston rings........................................................................................... 490 Tools.................................................................................................................. 490 Installation........................................................................................................... 490 13 48 37 Disassembling and assembling crankshaft........................................................................... 494 Tools.................................................................................................................. 494 Disassembling crankshaft............................................................................................... 496 Identifying the ring knurled screw................................................................................. 497 Pressing ring knurled screw in and out................................................................................. 498 Pressing ring knurled screw out.................................................................................... 498 Pressing ring knurled screw in..................................................................................... 499 Assembling crankshaft.................................................................................................. 499 13 73 37 Disassembling and assembling belt tensioner....................................................................... 503 Assembly note.......................................................................................................... 505 13 78 19 Removing and installing drive belt (engine installed)............................................................. 506 Removal overview of the drive belt (engine installed).................................................................. 506 Remove drive belt...................................................................................................... 507 Installation overview of the drive belt (engine installed)............................................................. 509 Install drive belt..................................................................................................... 511 15 CYLINDER HEAD, VALVE DRIVE.................................................................................................. 0 15 03 21 Removing camshaft housing engine removed........................................................................ 513 Tools.................................................................................................................. 513 Component overview and tightening torques.............................................................................. 513 Removing the camshaft housing.......................................................................................... 516 15 03 23 Installing camshaft housing....................................................................................... 521 15 05 02 Checking camshafts (timing) engine removed...................................................................... 523 Tools.................................................................................................................. 523 Checking camshafts..................................................................................................... 524 15 05 16 Setting camshafts (timing) engine removed....................................................................... 530 Tools.................................................................................................................. 530 Setting the camshafts (timing)......................................................................................... 531 15 05 19 Removing and installing camshafts engine removed................................................................ 537 Tools.................................................................................................................. 537 Component overview and tightening torques.............................................................................. 538 Removing camshafts..................................................................................................... 540 Installing camshafts................................................................................................... 544 15 20 37 Disassembling and assembling intermediate shaft................................................................... 550 15 55 19 Removing and installing hydraulic valve........................................................................... 552 Removing the hydraulic valve........................................................................................... 552 Installing the hydraulic valve......................................................................................... 554 15 70 21 Removing cylinder head............................................................................................ 557 Removing cylinder head................................................................................................. 559 15 70 23 Installing cylinder head.......................................................................................... 560 17 LUBRICATION................................................................................................................. 0 17 04 19 Removing and installing oil pressure sender....................................................................... 562 Removal................................................................................................................ 562 Installation........................................................................................................... 563 17 07 19 Removing and installing oil temperature sensor.................................................................... 565 Removal................................................................................................................ 565 Installation........................................................................................................... 566 17 28 19 Removing and installing check valve engine installed............................................................ 568 Removal................................................................................................................ 569 Installation........................................................................................................... 571 17 40 19 Removing and installing oil cooler Engine removed............................................................... 573 Removing oil cooler.................................................................................................... 573 Installing oil cooler.................................................................................................. 574 17 52 19 Removing and installing oil container............................................................................. 577 Removing oil container - removal overview.............................................................................. 577 Installing oil container............................................................................................... 580 COOLING........................................................................................................................ 0 19 38 17 Draining and filling in coolant................................................................................... 583 Draining coolant....................................................................................................... 584 Filling in coolant..................................................................................................... 584 Bleeding the cooling system............................................................................................ 584 19 40 19 Removing and installing coolant expansion tank.................................................................... 586 Removal................................................................................................................ 586 Installation........................................................................................................... 590 19 50 19 Removing and installing coolant pump (engine installed)........................................................... 592 Tools.................................................................................................................. 592 Removal................................................................................................................ 592 Installation........................................................................................................... 597 19 58 19 Removing and installing coolant regulator.........................................................................2093 Removal overview of the coolant regulator..............................................................................2093 Installation overview of the coolant regulator.........................................................................2096 19 62 19 Removing and installing coolant hose at front left (Y-type coolant distributor)................................... 601 Tools.................................................................................................................. 601 Removal................................................................................................................ 601 Installation........................................................................................................... 603 GROUP 2 FUEL, EXHAUST, POWER SUPPLY, DME........................................................................................... 0 20 FUEL SUPPLY, CONTROL........................................................................................................ 0 Precautionary measures when working on fuel system......................................................................... 124 20 02 01 Checking fuel pressure............................................................................................ 606 20 10 19 Removing and installing fuel tank................................................................................. 609 Removing fuel tank..................................................................................................... 611 Installing fuel tank................................................................................................... 616 Tightening torques for front axle and fuel tank.................................................................... 620 20 15 01 Calibrating fuel level sensor system.............................................................................. 622 20 39 19 Removing and installing fuel return line.......................................................................... 623 Removal................................................................................................................ 623 Installation........................................................................................................... 624 20 60 55 Replacing fuel filter............................................................................................. 626 Removing fuel filter................................................................................................... 626 20 66 01 Checking quantity delivered by fuel pump.......................................................................... 631 20 68 19 Removing and installing fuel cooler............................................................................... 634 Removing fuel cooler................................................................................................... 634 Installing fuel cooler................................................................................................. 635 21 EXHAUST SYSTEM, TURBOCHARGING............................................................................................... 0 21 10 19 Removing and installing air guide for charge air cooling.......................................................... 636 Removing air guide for charge air cooling.............................................................................. 636 Installing air guide for charge air cooling............................................................................ 638 21 30 19 Removing and installing turbocharger.............................................................................. 640 Removing turbocharger.................................................................................................. 640 Installing turbocharger................................................................................................ 642 21 43 19 Removing and installing the charge air cooler..................................................................... 646 Removing the charge air cooler......................................................................................... 646 Installing the charge air cooler....................................................................................... 647 21 67 05 Checking and adjusting the bypass flap control boxes on the turbocharger.......................................... 648 Check and adjust (cylinder bank 1 - 3)................................................................................. 648 Test............................................................................................................... 648 Adjusting.......................................................................................................... 649 Check and adjust (cylinder bank 4 - 6)................................................................................. 649 21 67 19 Removing and installing bypass flap control box on the turbocharger - Engine installed............................ 651 Removing bypass flap control box on the turbocharger................................................................... 651 Installing bypass flap control box on the turbocharger................................................................. 652 21 75 20 Removing and installing oil container for exhaust turbocharger - Engine installed................................. 654 Removing oil container for exhaust turbocharger........................................................................ 654 Installing oil container for exhaust turbocharger...................................................................... 656 21 80 19 Removing and installing oil pump for turbocharger................................................................. 658 Tools.................................................................................................................. 658 Removal................................................................................................................ 658 Installation........................................................................................................... 667 21 90 19 Removing and installing pressure sensor........................................................................... 672 Removal................................................................................................................ 672 Installation........................................................................................................... 672 24 FUEL SYSTEM, ELECTRONIC INJECTION........................................................................................... 0 24 00 33 Completing the vacuum connections................................................................................. 673 24 25 19 Removing and installing air cleaner............................................................................... 676 Removing air cleaner................................................................................................... 676 Installing air cleaner................................................................................................. 678 24 40 20 Removing and installing injection valves - Engine removed.........................................................1246 Removing injection valves of cylinder bank 1 3.......................................................................1246 Removing injection valves of cylinder bank 4 6.......................................................................1247 Installing injection valves of cylinder bank 1 3.....................................................................1247 Installing injection valves of cylinder bank 4 6.....................................................................1248 24 40 20 Removing and installing injection valves - Engine installed.......................................................1249 Preliminary work.......................................................................................................1249 Removing injection valves of cylinder bank 1 3.......................................................................1249 Removing injection valves of cylinder bank 4 6.......................................................................1253 Installing injection valves............................................................................................1255 24 42 19 Removing and installing throttle body - Engine installed.......................................................... 680 Removing throttle body................................................................................................. 680 Installing throttle body............................................................................................... 681 24 46 01 Testing the intake distributor (leak test)........................................................................ 683 Tools.................................................................................................................. 683 Leak test.............................................................................................................. 683 24 46 20 Removing and installing intake distributor Engine removed....................................................... 685 Removing intake distributor............................................................................................ 685 Installing intake distributor.......................................................................................... 687 24 46 37 Disassembling and assembling intake distributor................................................................... 690 Disassembling the intake distributor................................................................................... 690 Vacuum lines........................................................................................................... 692 24 69 19 Precautionary measures when handling oxygen sensors............................................................... 694 24 69 19 Removing and installing oxygen sensors in front of catalytic converter............................................1263 Tools..................................................................................................................1263 Removing oxygen sensors in front of catalytic converter................................................................1263 Oxygen sensor, left side :.........................................................................................1264 Oxygen sensor, right side :........................................................................................1265 Installing oxygen sensors in front of catalytic converter..............................................................1265 24 70 19 Removing and installing DME control module........................................................................1267 Obtaining read-out and saving vehicle data from DME control module.....................................................1268 Removing DME control module............................................................................................1268 Installing the DME control module......................................................................................1269 Programming the new DME control module 911 Turbo (996).................................................................1270 Programming the new DME control module - GT2 and version X51...........................................................1271 Programming the DME control module 911 Turbo (996).....................................................................1272 Programming DME control module - GT2 and version X51...................................................................1273 Version (data records) 911 Turbo (996).................................................................................1275 Version (data records) - GT2...........................................................................................1276 24 73 19 Removing and installing oxygen sensors behind catalytic converter................................................. 695 Removing oxygen sensors behind the catalytic converter................................................................. 695 Oxygen sensor, left side :......................................................................................... 696 Oxygen sensor, right side :........................................................................................ 696 Installing oxygen sensors behind the catalytic converter............................................................... 697 26 EXHAUST SYSTEM.............................................................................................................. 0 26 01 05 Exhaust system leak test.......................................................................................... 698 Tools.................................................................................................................. 698 Leak test.............................................................................................................. 699 26 33 19 Removing and installing rear mufflers............................................................................. 700 Removing rear mufflers................................................................................................. 700 Installing rear mufflers............................................................................................... 702 26 65 19 Removing and installing secondary air pump........................................................................ 704 Removal................................................................................................................ 704 Installation........................................................................................................... 705 27 STARTER, POWERSUPPLY, CRUISE CONTROL........................................................................................ 0 27 06 Battery.............................................................................................................. 387 Battery - handling notes............................................................................................... 387 Warning notes and safety regulations for hydrocyanic acid batteries................................................ 388 Removing and installing battery........................................................................................ 388 Remove battery......................................................................................................... 389 Install battery........................................................................................................ 390 Visual inspection...................................................................................................... 391 Check acid level....................................................................................................... 391 Checking gravity of electrolyte........................................................................................ 392 Open-circuit voltage measurement....................................................................................... 393 Battery load test...................................................................................................... 394 Charging battery....................................................................................................... 395 27 06 Electrical emergency release, front cover............................................................................ 397 Emergency release, front cover......................................................................................... 397 27 22 19 Removing and installing three-phase generator..................................................................... 706 Removing the three-phase generator..................................................................................... 706 Installing the three-phase generator................................................................................... 707 Undoing and tightening the belt pulley................................................................................. 707 Tool for holding the free-wheel pulley................................................................................. 707 27 27 19 Removing and installing bracket for generator..................................................................... 709 Removing bracket for generator......................................................................................... 709 Removal............................................................................................................ 709 Installing bracket for generator....................................................................................... 712 27 60 19 Removing and installing starter (manual transmission)............................................................. 715 Removing the starter................................................................................................... 715 Installing the starter................................................................................................. 715 27 60 19 Removing and installing starter (automatic transmission)..........................................................1277 Removing the starter...................................................................................................1277 Installing the starter.................................................................................................1278 28 IGNITION SYSTEM............................................................................................................. 0 28 39 19 Removing and installing hall sender - Engine installed............................................................ 716 Removing hall sender................................................................................................... 716 Installing hall sender................................................................................................. 717 Tightening torques..................................................................................................... 718 28 70 55 Replacing the spark plugs......................................................................................... 719 Removing spark plugs................................................................................................... 719 Installing spark plugs................................................................................................. 720 28 72 20 Removing and installing knock sensor Engine removed............................................................. 722 Removing and installing knock sensor, cylinder bank 1-3................................................................ 722 Removing knock sensor, cylinder bank 4 - 6............................................................................. 723 Installing knock sensor, cylinder bank 4 - 6........................................................................... 724 GROUP 3 TRANSMISSION............................................................................................................... 0 3 TECHNICAL DATA............................................................................................................... 0 3 Technical data - Manual.................................................................................................. 209 6-speed manual transmission G 96.50.................................................................................... 209 Manual transmission tightening torques............................................................................. 210 Front wheel drive Z 96.00.............................................................................................. 210 Front-axle drive tightening torques................................................................................ 211 3 Technical data - Tiptronic............................................................................................... 212 5-speed Tiptronic transmission A 96.50-150............................................................................. 212 Tightening torques for Tiptronic transmission...................................................................... 213 Front wheel drive Z 96.00.............................................................................................. 214 Front-axle drive tightening torques................................................................................ 214 3 Technical Data - GT2.....................................................................................................1876 6-speed manual transmission G 96.88....................................................................................1876 Manual transmission tightening torques.............................................................................1877 MANUAL TRANSMISSION............................................................................................................ 0 30 CLUTCH, ACTUATION....................................................................................................... 0 30 Clutch: checking fluid levels....................................................................................... 310 General............................................................................................................ 310 Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment and luggage compartment....................... 310 Checking Pentosin CHF 11 S hydraulic fluid in the engine compartment............................................... 311 Checking Pentosin CHF 11 S hydraulic fluid in the luggage compartment.............................................. 312 30 01 01 Checking clutch booster circuit............................................................................... 726 1. Checking accumulator............................................................................................ 726 2. Checking valve (pressure-regulating valve)...................................................................... 726 2.1 Checking the valve (pressure-regulating valve) in the clutch save cylinder................................. 727 2.2 Checking the valve (pressure-regulating valve) in the upper part of the expansion tank..................... 727 30 01 07 Bleeding clutch operation..................................................................................... 729 Disposal of Pentosin............................................................................................... 730 30 01 07 Bleeding the clutch system - GT2..............................................................................1913 Filling/bleeding...................................................................................................1913 30 27 19 Removing and installing clutch pressure hose - Engine installed............................................... 731 Removing clutch pressure hose...................................................................................... 731 Installing clutch pressure hose.................................................................................... 732 30 30 19 Removing and installing clutch slave cylinder................................................................. 734 Removal............................................................................................................ 734 Tightening torques................................................................................................. 736 Installation....................................................................................................... 737 30 31 19 Removing and installing the accumulator....................................................................... 739 Removal............................................................................................................ 739 Installation....................................................................................................... 740 30 45 19 Removing and installing release bearing (clutch removed)...................................................... 742 Removing release bearing........................................................................................... 743 Installing release bearing......................................................................................... 743 30 45 19 Removing and installing release bearing (clutch removed) - GT2................................................1915 Removing release bearing...........................................................................................1916 Installing release bearing.........................................................................................1916 30 50 19 Removing and installing clutch................................................................................ 745 Tools.............................................................................................................. 745 Removing clutch.................................................................................................... 745 Installing clutch.................................................................................................. 746 Tightening torques................................................................................................. 746 30 50 19 Removing and installing clutch - GT2..........................................................................1918 Tools..............................................................................................................1918 Removing clutch....................................................................................................1918 Installing clutch..................................................................................................1919 Tightening torques.................................................................................................1919 30 50 37 Disassembling and assembling clutch........................................................................... 747 30 50 37 Disassembling and assembling clutch - GT2.....................................................................1920 30 56 01 Checking clutch drive plate for wear.......................................................................... 748 34 ACTUATION, HOUSING...................................................................................................... 0 34 01 55 Changing transmission oil..................................................................................... 773 Changing transmission oil.......................................................................................... 773 Tightening torques................................................................................................. 773 34 08 19 Removing and installing shift console......................................................................... 774 Tools.............................................................................................................. 774 Removing and installing shift console.............................................................................. 774 Removing shift console............................................................................................. 775 Installing shift console........................................................................................... 776 Tightening torques................................................................................................. 777 34 12 19 Removing and installing shift and selector cables............................................................. 778 Tools.............................................................................................................. 778 Removing and installing shift and selector cables.................................................................. 778 Removing shift and selector cables............................................................................. 779 Installing shift and selector cables........................................................................... 781 Tightening torques................................................................................................. 782 34 35 27 Removing and refitting the transmission....................................................................... 783 Tools.............................................................................................................. 783 Removing transmission.............................................................................................. 783 Refitting transmission............................................................................................. 785 Tightening torques................................................................................................. 786 34 35 37 Partially disassembling transmission..........................................................................1279 Tools..............................................................................................................1279 Removing transmission cover........................................................................................1280 Disassembling front gear set.......................................................................................1280 Overview.......................................................................................................1280 Disassembling gear set.........................................................................................1282 Removing gear housing..............................................................................................1283 Removing input and output shaft....................................................................................1284 Overview.......................................................................................................1284 Removing shafts................................................................................................1285 Dismantling input shaft............................................................................................1286 Overview.......................................................................................................1286 Disassembling shaft............................................................................................1288 34 35 37 Assembling transmission.......................................................................................1289 Tools..............................................................................................................1289 Assembling input shaft.............................................................................................1290 Assembling shafts..............................................................................................1290 Tightening torques.............................................................................................1291 Installing input and output shaft..................................................................................1291 Installing shafts..............................................................................................1291 Tightening torques.............................................................................................1294 Fitting gear housing...............................................................................................1295 Fitting housing................................................................................................1295 Tightening torques.............................................................................................1295 Assembling front gear set..........................................................................................1295 Assembling gear set............................................................................................1295 Tightening torques.............................................................................................1297 Fitting front transmission case cover..............................................................................1298 Fitting cover..................................................................................................1298 Tightening torques.............................................................................................1298 34 49 19 Removing and installing closure cap for selector force mechanism.............................................. 787 Tools.............................................................................................................. 787 Removing and installing closure cap for selector force mechanism................................................... 787 Removing closure cap for selector force mechanism.............................................................. 788 Installing closure cap for selector force mechanism............................................................ 789 Tightening torques................................................................................................. 789 GT2 SPECIAL SECTION.................................................................................................... 0 34 01 55 Changing transmission oil - GT2...........................................................................1921 Changing transmission oil - GT2................................................................................1921 Topping up transmission oil - GT2..............................................................................1921 Tightening torques.............................................................................................1922 34 35 27 Removing and refitting the transmission - GT2.............................................................1923 Tools..........................................................................................................1923 Removing transmission..........................................................................................1923 Refitting transmission.........................................................................................1924 Tightening torques.............................................................................................1926 34 35 37 Disassembling transmission - GT2..........................................................................1994 Tools..........................................................................................................1994 Removing transmission cover....................................................................................1995 Disassembling front gear set...................................................................................1995 Overview...................................................................................................1995 Disassembling gear set.....................................................................................1997 Removing gear housing..........................................................................................1998 Removing input and output shaft................................................................................1998 Overview...................................................................................................1999 Removing shafts............................................................................................2000 Disassembling output shaft.....................................................................................2001 Overview...................................................................................................2001 Disassembling shaft........................................................................................2002 Dismantling input shaft........................................................................................2002 Overview...................................................................................................2002 Disassembling shaft........................................................................................2004 34 35 37 Assembling transmission - GT2.............................................................................2005 Tools..........................................................................................................2005 Assembling input shaft.........................................................................................2005 Assembling shafts..........................................................................................2006 Tightening torques.........................................................................................2007 Assembling input shaft.........................................................................................2007 Assembling shaft...........................................................................................2007 Installing input and output shaft..............................................................................2007 Installing shafts..........................................................................................2007 Tightening torques.........................................................................................2010 Fitting gear housing...........................................................................................2011 Fitting housing............................................................................................2011 Tightening torques.........................................................................................2011 Assembling front gear set......................................................................................2011 Assembling gear set........................................................................................2011 Tightening torques.........................................................................................2013 Fitting front transmission case cover..........................................................................2014 Fitting cover..............................................................................................2014 Tightening torques.........................................................................................2014 34 37 37 Disassembling and assembling transmission housing - GT2...................................................1927 Tools..........................................................................................................1927 Overview.......................................................................................................1928 Disassembly and assembly instructions..........................................................................1930 Disassembly................................................................................................1930 Assembly...................................................................................................1930 Tightening torques.............................................................................................1931 34 52 37 Disassembling and assembling gear housing - GT2...........................................................1932 Tools..........................................................................................................1932 Overview.......................................................................................................1933 Disassembling gear housing.....................................................................................1934 Disassembling gearshift....................................................................................1934 Removing outer bearing race................................................................................1935 Removing ball sleeves......................................................................................1935 Removing screw plug........................................................................................1935 Assembling gear housing........................................................................................1935 Assembling gearshift.......................................................................................1936 Installing outer bearing race..............................................................................1936 Installing ball sleeves....................................................................................1936 Installing screw plug......................................................................................1936 Tightening torques.............................................................................................1936 34 55 37 Disassembling and assembling front transmission cover GT2...............................................1938 Tools..........................................................................................................1938 Overview.......................................................................................................1939 Disassembling front transmission case cover....................................................................1940 Disassembling reverse idler gear...........................................................................1940 Dismantling cylinder-roller bearing........................................................................1940 Disassembling outer bearing race...........................................................................1941 Assembling front transmission case cover.......................................................................1942 Fitting reverse idler gear.................................................................................1942 Fitting cylindrical-roller bearing.........................................................................1942 Fitting outer bearing race.................................................................................1943 Tightening torques.............................................................................................1943 34 72 19 Removing and installing transmission oil pump - GT2.......................................................1944 Tools..........................................................................................................1944 Removing transmission oil pump.................................................................................1944 Installing transmission oil pump...............................................................................1945 Tightening torques.............................................................................................1945 34 74 19 Removing and installing transmission oil cooler - GT2.....................................................1946 Tools..........................................................................................................1946 Overview.......................................................................................................1946 Removing transmission oil cooler...............................................................................1947 Installing transmission oil cooler.............................................................................1949 Tightening torques.............................................................................................1949 35 GEARS, SHAFTS........................................................................................................... 0 35 50 19 Removing and installing sealing ring for input shaft..........................................................1299 Tools..............................................................................................................1299 Removing sealing ring for input shaft..............................................................................1299 Installing sealing ring for input shaft............................................................................1300 Tightening torques.................................................................................................1301 35 50 19 Removing and installing sealing ring for drive shaft - GT2....................................................1951 Tools..............................................................................................................1951 Removing sealing ring for drive shaft..............................................................................1951 Installing sealing ring for drive shaft............................................................................1952 Tightening torques.................................................................................................1953 39 FINAL DRIVE, DIFFERENTIAL............................................................................................... 0 39 02 19 Removing and installing cardan shaft..........................................................................1311 Tools..............................................................................................................1311 Removing cardan shaft..............................................................................................1311 Installing cardan shaft............................................................................................1312 Tightening torques.................................................................................................1313 39 22 19 Removing and installing sealing ring for halfshaft flange.....................................................1317 Tools..............................................................................................................1317 Removing sealing ring for halfshaft flange.........................................................................1317 Installing sealing ring for halfshaft flange.......................................................................1318 Tightening torques.................................................................................................1318 39 58 19 Removing and installing lid for front wheel drive.............................................................1325 Tools..............................................................................................................1325 Removing the lid for front wheel drive.............................................................................1325 Installing the lid for front wheel drive...........................................................................1326 Tightening torques.................................................................................................1326 39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive)....................................1329 Tools..............................................................................................................1329 Removing the sealing ring for the flanged shaft (front wheel drive)................................................1329 Installing the sealing ring for the flanged shaft (front wheel drive)..............................................1330 39 60 01 Checking function of installed viscous clutch.................................................................1335 Test conditions....................................................................................................1335 Checking function of installed viscous clutch......................................................................1335 39 60 19 Removing and installing the viscous clutch....................................................................1341 Tools..............................................................................................................1341 Removing the viscous clutch........................................................................................1342 Installing the viscous clutch......................................................................................1342 Tightening torques.................................................................................................1343 39 62 19 Removing and installing support for front wheel drive.........................................................1347 Removing the support for front wheel drive.........................................................................1347 Installing the support for front wheel drive.......................................................................1347 Tightening torques.................................................................................................1348 39 82 19 Removing and installing sealing ring for cardan flange........................................................1351 Tools..............................................................................................................1351 Removing sealing ring for cardan flange............................................................................1351 Installing sealing ring for cardan flange..........................................................................1352 Tightening torques.................................................................................................1353 39 88 19 Removing and installing front wheel drive.....................................................................1357 Remove front wheel drive...........................................................................................1357 Installing the front wheel drive...................................................................................1358 Tightening torques.................................................................................................1359 39 90 55 Replacing and checking transmission oil in final drive........................................................1363 Tools..............................................................................................................1363 Changing transmission oil in final drive...........................................................................1363 Tightening torques.................................................................................................1365 39 90 55 Changing transmission oil in front wheel drive................................................................1366 Changing transmission oil in front wheel drive.....................................................................1366 Tightening torques.................................................................................................1366 GT2 SPECIAL SECTION.................................................................................................... 0 39 08 15 Adjusting drive set - GT2.................................................................................1955 Tools..........................................................................................................1955 Sequence of adjustment operations..............................................................................1956 Determining disc thickness S4 and S5...........................................................................1956 Determining disc thickness S3..................................................................................1958 Determining disc thickness S1 and S2...........................................................................1960 Determining total disc thickness S1 + S2...................................................................1960 Dividing the total disc thickness into S1 and S2...........................................................1961 Checking the circumferential backlash and setting, if necessary............................................1961 39 22 19 Removing and installing sealing ring for halfshaft flange - GT2...........................................1964 Tools..........................................................................................................1964 Removing sealing ring for halfshaft flange.....................................................................1964 Installing sealing ring for halfshaft flange...................................................................1965 Tightening torques.............................................................................................1966 39 40 19 Removing and installing differential and differential lock - GT2..........................................1967 Tools..........................................................................................................1967 Overview.......................................................................................................1967 Removing differential and differential lock....................................................................1969 Installing diffential and differential lock....................................................................1969 Tightening torques.............................................................................................1969 39 40 37 Assembling and disassembling differential and differential lock - GT2.....................................1970 Tools..........................................................................................................1970 Overview.......................................................................................................1970 Disassembling GKN differential lock............................................................................1972 Assembling GKN differential lock...............................................................................1972 Tightening torques.............................................................................................1973 AUTOMATIC TRANSMISSION......................................................................................................... 64 32 TORQUE CONVERTER........................................................................................................ 0 32 47 19 Removing and installing torque-converter sealing ring......................................................... 759 Tools.............................................................................................................. 759 Removing the torque-converter sealing ring......................................................................... 759 Installing the torque-converter sealing ring....................................................................... 760 32 50 19 Removing and installing torque converter...................................................................... 761 Tools.............................................................................................................. 761 Removing the torque converter...................................................................................... 761 Installing the torque converter.................................................................................... 762 37 ACTUATION, HOUSING...................................................................................................... 0 37 02 35 Checking and topping up the ATF............................................................................... 794 Tools.............................................................................................................. 794 Checking and topping up the ATF.................................................................................... 794 Tightening torques................................................................................................. 796 37 02 55 Replacing ATF fluid........................................................................................... 797 Tools.............................................................................................................. 797 Replacing ATF fluid................................................................................................ 797 Tightening torques................................................................................................. 799 37 04 19 Removing and installing selector knob.........................................................................1303 Removing selector knob.............................................................................................1303 Installing selector knob...........................................................................................1303 37 08 19 Removing and installing selector support...................................................................... 800 Removing and installing selector support........................................................................... 800 Removing selector support...................................................................................... 800 Installing selector support.................................................................................... 801 Tightening torques................................................................................................. 802 37 15 19 Removing and installing selector lever cable.................................................................. 803 Tools.............................................................................................................. 803 Removing and installing selector lever cable....................................................................... 803 Removing selector support...................................................................................... 803 Installing selector support.................................................................................... 806 Tightening torques................................................................................................. 807 37 30 19 Removing and installing Tiptronic control module..............................................................1305 Removing the control module........................................................................................1305 Installing the control module......................................................................................1307 Coding the Tiptronic control module................................................................................1308 Tightening torques.................................................................................................1309 Tools..............................................................................................................1309 37 35 27 Removing and refitting the transmission....................................................................... 809 Tools.............................................................................................................. 809 Removing transmission.............................................................................................. 810 Refitting transmission............................................................................................. 811 Tightening torques................................................................................................. 812 37 58 19 Removing and installing ATF filter............................................................................ 813 Tools.............................................................................................................. 813 Removing ATF filter................................................................................................ 813 Installing ATF filter.............................................................................................. 814 Tightening torques................................................................................................. 815 38 GEARS, CONTROL.......................................................................................................... 0 38 77 19 Removing and installing electrohydraulic control unit......................................................... 816 Tools.............................................................................................................. 816 Removing the electrohydraulic control unit......................................................................... 816 Installing the electrohydraulic control unit....................................................................... 819 Tightening torques................................................................................................. 821 38 77 37 Disassembling and assembling electrohydraulic control unit.................................................... 822 Tools.............................................................................................................. 822 Overview........................................................................................................... 822 Disconnecting hydraulic and electrical control unit................................................................ 824 Removing solenoid and control valve................................................................................ 824 Installing solenoid and control valve.............................................................................. 824 Reassembling the hydraulic and electrical control unit............................................................. 824 39 FINAL DRIVE, DIFFERENTIAL............................................................................................... 0 39 02 19 Removing and installing cardan shaft..........................................................................1314 Tools..............................................................................................................1314 Removing and installing cardan shaft...............................................................................1314 Removing cardan shaft..........................................................................................1314 Installing cardan shaft........................................................................................1315 Tightening torques.................................................................................................1316 39 22 19 Removing and installing sealing ring for short flanged shaft..................................................1319 Tools..............................................................................................................1319 Removing and installing sealing ring for short flanged shaft.......................................................1319 Removing sealing ring for short flanged shaft..................................................................1319 Installing sealing ring for short flanged shaft................................................................1321 Tightening torques.................................................................................................1321 39 25 19 Removing and installing long flanged shaft....................................................................1322 Tools..............................................................................................................1322 Removing and installing long flanged shaft.........................................................................1322 Removing long flanged shaft....................................................................................1322 Installing long flanged shaft..................................................................................1323 Tightening torques.................................................................................................1323 39 58 19 Removing and installing lid for front wheel drive.............................................................1327 Tools..............................................................................................................1327 Removing the lid for front wheel drive.............................................................................1327 Installing the lid for front wheel drive...........................................................................1328 Tightening torques.................................................................................................1328 39 59 19 Removing and installing sealing ring for flanged shaft (front wheel drive)....................................1332 Tools..............................................................................................................1332 Removing the sealing ring for the flanged shaft (front wheel drive)................................................1332 Installing the sealing ring for the flanged shaft (front wheel drive)..............................................1333 39 60 01 Checking function of installed viscous clutch.................................................................1338 Test conditions....................................................................................................1338 Checking function of installed viscous clutch......................................................................1338 39 60 19 Removing and installing the viscous clutch....................................................................1344 Tools..............................................................................................................1344 Removing the viscous clutch........................................................................................1345 Installing the viscous clutch......................................................................................1345 Tightening torques.................................................................................................1346 39 62 19 Removing and installing support for front wheel drive.........................................................1349 Removing the support for front wheel drive.........................................................................1349 Installing the support for front wheel drive.......................................................................1349 Tightening torques.................................................................................................1350 39 82 19 Removing and installing sealing ring for cardan flange........................................................1354 Tools..............................................................................................................1354 Removing and installing sealing ring for cardan flange.............................................................1354 Removing sealing ring for cardan flange........................................................................1354 Installing sealing ring for cardan flange......................................................................1355 Tightening torques.................................................................................................1356 39 88 19 Removing and installing front wheel drive.....................................................................1360 Removing front wheel drive.........................................................................................1360 Installing the front wheel drive...................................................................................1361 Tightening torques.................................................................................................1362 39 90 55 Changing transmission oil in front wheel drive................................................................1368 Changing transmission oil in front wheel drive.....................................................................1368 Tightening torques.................................................................................................1368 GROUP 4 RUNNING GEAR............................................................................................................... 0 4 NOTES........................................................................................................................ 0 4 Removing transport lock (spring strut locking devices) Turbo and GT2................................................... 216 General................................................................................................................ 216 Removing spring strut locking devices.................................................................................. 216 4 Lifting the vehicle...................................................................................................... 218 Lift the vehicle....................................................................................................... 218 4 Tests/notes for all-wheel drive.......................................................................................... 219 Balancing wheels on vehicle............................................................................................ 219 Power test............................................................................................................. 219 Brake test............................................................................................................. 219 Towing manual transmission vehicles.................................................................................... 219 Towing Tiptronic vehicles.............................................................................................. 219 4 Switching off PSM........................................................................................................ 220 Switching off PSM...................................................................................................... 220 Switching PSM back on.................................................................................................. 220 Characteristic features of Tiptronic vehicles (slip upshift)........................................................... 221 GT2 SPECIAL NOTES.......................................................................................................... 0 4 Running gear, general - GT2..........................................................................................1878 General............................................................................................................1878 4 Notes on repair instructions - GT2...................................................................................1880 General............................................................................................................1880 Tightening torques.................................................................................................1880 Adjustment operations on the spring struts.........................................................................1880 Suspension alignment...............................................................................................1881 Wheel removal/installation.........................................................................................1881 Brake - General....................................................................................................1882 Brake booster......................................................................................................1882 4 Tests / notes GT2..................................................................................................1883 Note...............................................................................................................1883 Lifting platform / test stands.....................................................................................1883 Wheel alignment platform...........................................................................................1883 Brake test.........................................................................................................1883 Power test.........................................................................................................1883 Front and rear stabilizer setting..................................................................................1884 Spoiler setting....................................................................................................1884 Racing camber values...............................................................................................1885 40 FRONT SUSPENSION............................................................................................................ 0 40 Tightening torques for front axle....................................................................................... 314 Cross member/side member (1 component)................................................................................. 314 Diagonal brace......................................................................................................... 314 Control arm............................................................................................................ 314 Spring strut/wheel carrier............................................................................................. 315 Front-axle final drive/drive shaft (Turbo)............................................................................. 315 Stabilizer............................................................................................................. 316 Steering............................................................................................................... 316 Wheel fastening........................................................................................................ 316 40 Disassembling and assembling front spring strut......................................................................... 402 Tools.................................................................................................................. 402 Disassembly and assembly instructions.................................................................................. 404 Disassembly........................................................................................................ 404 Distinguishing feature of coil springs and dampers................................................................. 405 Preliminary work and notes on assembly............................................................................. 405 Assembly........................................................................................................... 406 40 Disassembling and assembling front spring strut GT2...................................................................1900 Notes about adjustment work on the spring struts.......................................................................1900 Disassembling and assembling front spring strut GT2..................................................................1901 Disassembly and assembly instructions..................................................................................1902 Disassembly........................................................................................................1902 Preliminary work and notes on assembly.............................................................................1903 Assembly...........................................................................................................1903 40 09 Front-axle cross member - permissible combinations................................................................... 399 New front-axle cross member - as of model '02.......................................................................... 399 Allocating the front-axle cross member to the body..................................................................... 399 Impermissible combination.......................................................................................... 400 Permissible combinations........................................................................................... 400 Impermissible combination.......................................................................................... 401 40 41 19 Removing and installing the front drive shaft..................................................................... 826 Tools.................................................................................................................. 826 Removal................................................................................................................ 826 Installation........................................................................................................... 828 40 85 19 Removing and installing front spring strut........................................................................ 829 Removal................................................................................................................ 829 Installation........................................................................................................... 830 42 REAR SUSPENSION............................................................................................................. 0 42 Tightening torques for rear axle........................................................................................ 318 Carrier side section/cross member...................................................................................... 318 Axle strut............................................................................................................. 318 Wheel carrier.......................................................................................................... 319 Spring strut........................................................................................................... 319 Drive shaft/stabilizer................................................................................................. 320 Unit mount............................................................................................................. 320 42 Disassembling and assembling rear spring strut - GT2....................................................................1906 Notes about adjustment work on the spring struts.......................................................................1906 Disassembling and assembling rear spring strut - GT2...................................................................1907 Disassembly and assembly instructions..................................................................................1909 Disassembly........................................................................................................1909 Preliminary work and notes on assembly.............................................................................1909 Assembly...........................................................................................................1910 42 21 19 Removing and installing rear drive shaft (manual transmission)....................................................1370 Tools..................................................................................................................1370 Removing the drive shaft (manual transmission).........................................................................1370 Installing the drive shaft (manual transmission).......................................................................1373 42 21 19 Removing and installing rear drive shaft (Tiptronic transmission).................................................1376 Tools..................................................................................................................1376 Removing the drive shaft (Tiptronic transmission)......................................................................1376 Installing the drive shaft (Tiptronic transmission)....................................................................1379 42 58 19 Removing and installing rear-wheel bearing........................................................................ 832 Tools.................................................................................................................. 832 Removing and installing rear-wheel bearing......................................................................... 832 Notes on removal and installation...................................................................................... 833 Removal............................................................................................................ 834 Installation....................................................................................................... 835 42 71 Disassembling and assembling rear spring strut - Turbo............................................................... 409 Tools.................................................................................................................. 409 Disassembling and assembling rear spring strut......................................................................... 409 Disassembly and assembly instructions.................................................................................. 411 Disassembly........................................................................................................ 411 Distinguishing feature of coil springs and dampers................................................................. 413 Assembly........................................................................................................... 413 42 71 19 Removing and installing rear spring strut......................................................................... 836 Removal................................................................................................................ 836 Installation........................................................................................................... 836 44 WHEELS, TYRES, ALIGNMENT.................................................................................................... 0 44 Conversion table for wheel alignment values............................................................................. 321 Minutes in decimal degrees............................................................................................. 321 Conversion from minutes to decimal degrees (examples).............................................................. 321 Conversion from decimal degrees to minutes (examples).............................................................. 321 44 Adjusting values for suspension alignment - Turbo and GT2............................................................... 323 Vehicle height......................................................................................................... 323 Wheel alignment values................................................................................................. 323 44 Alignment card - Turbo.................................................................................................. 325 44 Suspension alignment, complete.......................................................................................... 327 Vehicle height/wheel load.............................................................................................. 328 Wheel-alignment corrections............................................................................................ 328 Rear axle.......................................................................................................... 328 Front axle......................................................................................................... 329 General procedure for suspension alignment............................................................................. 329 Vehicle height (vehicle height check).................................................................................. 330 General............................................................................................................ 330 Preliminary work................................................................................................... 330 Front axle......................................................................................................... 331 Rear axle.......................................................................................................... 331 Wheel alignment.................................................................................................... 331 Rear axle.............................................................................................................. 332 Adjusting camber................................................................................................... 332 Adjusting toe...................................................................................................... 333 Front axle............................................................................................................. 334 Adjusting camber................................................................................................... 334 Adjusting caster................................................................................................... 334 Adjusting toe...................................................................................................... 335 Toe-difference angle............................................................................................... 337 44 Wheel rims and tires.................................................................................................... 338 Tire condition / tire pressure......................................................................................... 338 Tire pressure of cold tires (approx. 20° C)............................................................................ 338 911 Turbo.......................................................................................................... 338 911 GT2 (M002/M003)................................................................................................ 338 Overview of tires and wheels (series).................................................................................. 339 Notes on mounting tires............................................................................................ 339 44 Tyres................................................................................................................... 340 Mounting instructions.................................................................................................. 340 General............................................................................................................ 340 Uncontrolled matching.............................................................................................. 341 Controlled matching................................................................................................ 341 Fitting............................................................................................................ 341 Balancing weights...................................................................................................... 342 Navigation system...................................................................................................... 342 Wheel storage.......................................................................................................... 342 Tyre age............................................................................................................... 343 44 Checking disc wheels.................................................................................................... 344 Checking the radial and lateral runout................................................................................. 344 44 Tyre mounting........................................................................................................... 345 Tools.................................................................................................................. 345 Notes on removing/mounting tyres....................................................................................... 346 Removal................................................................................................................ 346 Fitting................................................................................................................ 347 44 Balancing/optimising wheels............................................................................................. 350 General................................................................................................................ 350 Balancing/optimising wheels............................................................................................ 350 Further to 1: Mounting the tyre on the rim......................................................................... 351 Further to 2: Stationary balancing with optimisation of the rolling smoothness..................................... 351 Further to 3: Mounting the wheel on the vehicle.................................................................... 352 Further to 4: Electronic fine balancing............................................................................ 352 Further to 4a: Fine balancing of the front wheels.................................................................. 353 Further to 4b: Fine balancing of the rear wheels................................................................... 353 Balancing weights...................................................................................................... 354 Affixing the adhesive weights...................................................................................... 354 44 05 19 Removing and installing the wheel - Turbo and GT2................................................................. 838 Wheel mounting - Turbo and GT2......................................................................................... 838 Removing/installing the wheel on vehicle - Turbo and GT2............................................................... 838 44 27 Instructions for collapsible wheel/spare wheel - Turbo with PCCB..................................................... 416 Mounting collapsible spare wheel - Turbo with PCCB..................................................................... 416 Placing collapsible spare wheel in to the vehicle - Turbo with PCCB.................................................... 417 44 35 19 Removing and installing valve (steel valve) (Turbo ll wheel)...................................................... 841 General................................................................................................................ 841 Notes on removal and installation...................................................................................... 841 Removal................................................................................................................ 842 Installation........................................................................................................... 842 GT2 SPECIAL NOTES.......................................................................................................... 0 44 Alignment card - GT2................................................................................................1886 44 Suspension alignment - GT2..........................................................................................1888 Suspension alignment, complete.....................................................................................1888 Driving onto measuring platform....................................................................................1888 Tools..............................................................................................................1888 Deviating points for GT2...........................................................................................1889 Notes on height changes/wheel-load changes.........................................................................1890 Vehicle height GT2.................................................................................................1891 Wheel alignment....................................................................................................1892 Front-axle camber setting......................................................................................1893 Camber fine adjustment.........................................................................................1893 Camber/toe, rear axle..........................................................................................1894 Instructions for fitting diagonal control arm on control arm GT2.................................................1894 44 Tyre failure / tyre sealant GT2...................................................................................1896 Repair procedure...................................................................................................1896 45 ABS/PSM..................................................................................................................... 0 45 ABS/PSM 5.7 check with Porsche System Tester 2.......................................................................... 355 Test with Porsche System Tester 2...................................................................................... 355 45 11 19 Removing and installing front speed sensors....................................................................... 844 Removal................................................................................................................ 844 Installation........................................................................................................... 844 45 15 19 Removing and installing rear speed sensors........................................................................ 845 Removal................................................................................................................ 845 Installation........................................................................................................... 845 45 30 19 Removing and installing hydraulic unit............................................................................ 847 Replacing the hydraulic unit........................................................................................... 847 Removal................................................................................................................ 848 Installation........................................................................................................... 849 45 46 19 Removing and installing front ABS lead............................................................................1383 Removing front ABS lead................................................................................................1383 Installing front ABS lead..............................................................................................1385 Tightening torques.....................................................................................................1387 Tools..................................................................................................................1387 45 46 19 Removing and installing front ABS lead (GT2)......................................................................2015 Removing front ABS lead................................................................................................2015 Installing front ABS lead..............................................................................................2017 Tightening torques.....................................................................................................2018 Tools..................................................................................................................2018 45 46 19 Removing and installing rear ABS lead (Turbo & GT2)...............................................................1388 Removing rear ABS lead.................................................................................................1388 Installing rear ABS lead...............................................................................................1390 Tightening torques.....................................................................................................1393 Tools..................................................................................................................1393 45 59 19 Removing and installing rate-of-turn sensor....................................................................... 851 Removal................................................................................................................ 852 Installation........................................................................................................... 853 45 59 31 Conversion of rate-of-turn sensor................................................................................. 854 Overview of rate-of-turn sensor conversion............................................................................. 855 Removal................................................................................................................ 857 Fitting................................................................................................................ 859 45 60 Steering angle sensor................................................................................................ 418 Calibrating steering angle sensor...................................................................................... 418 Steering angle sensor position..................................................................................... 418 The steering angle sensor must be calibrated after:................................................................ 418 Calibrating steering angle sensor.................................................................................. 419 Check the steering angle sensor actual value in the following cases:............................................... 420 Checking the steering angle sensor actual value.................................................................... 420 45 60 19 Removing and installing steering angle sensor..................................................................... 862 Notes on steering wheel position during removal and installation....................................................... 862 Removal................................................................................................................ 862 Notes on replacing the steering angle sensor - vehicles prior to '03 model............................................. 864 Component overview................................................................................................. 865 Installation........................................................................................................... 866 45 64 19 Remove and install booster pump for PSM........................................................................... 870 Removal................................................................................................................ 870 Installation........................................................................................................... 871 46 BRAKES MECHANICAL........................................................................................................... 0 46 Checking brake light switch setting..................................................................................... 356 Brake light switch setting............................................................................................. 356 Checking brake light switch setting.................................................................................... 356 Adjusting switch if pedal travel is too small.......................................................................... 357 1st possibility:................................................................................................... 357 2nd possibility:................................................................................................... 357 Adjusting switch if pedal travel is too large...................................................................... 357 46 Tightening torques for mechanical brake................................................................................. 358 46 Technical data/Brake wear limit - Turbo................................................................................. 359 Technical data - Turbo with cast iron brake discs...................................................................... 359 Wear limit technical data - Turbo with cast iron brake discs........................................................... 360 46 Checking the thickness of the disc brake pads - Turbo and GT2........................................................... 361 46 Technical data/Brake wear limit - Turbo with PCCB....................................................................... 363 Technical data - Turbo with ceramic brake discs (PCCB)................................................................. 363 Wear limit technical data - Turbo with ceramic brake discs (PCCB)...................................................... 364 46 11 15 Adjusting the brake pushrod....................................................................................... 872 46 36 20 Removing and installing the front disc brake pads................................................................. 873 Removal................................................................................................................ 873 Installation........................................................................................................... 874 Bedding in the brake pads.......................................................................................... 875 46 38 20 Removing and installing the rear disc brake pads.................................................................. 876 Removal................................................................................................................ 876 Installation........................................................................................................... 877 Bedding in the brake pads.......................................................................................... 878 46 50 02 Checking front gray cast iron brake discs (wear assessment).......................................................1394 General................................................................................................................1394 1. Visual inspection for cracks and evaluating cracks..................................................................1394 Evaluating the cracks on the gray cast iron brake discs............................................................1395 2. Checking brake discs for minimum thickness..........................................................................1396 Notes on bedding in the new brake pads.................................................................................1397 46 50 02 Checking front PCCB brake discs (wear assessment).................................................................1398 General................................................................................................................1398 1. Visual inspection of the surfaces of the brake disc friction surfaces...............................................1398 PCCB brake disc wear appearance....................................................................................1399 2. Checking brake discs for minimum thickness..........................................................................1400 3. Checking brake discs for edge damage................................................................................1400 Note concerning bores (perforations) in the brake disc friction surface................................................1401 Note on bedding in the new brake pads..................................................................................1401 46 50 04 Measuring front brake discs....................................................................................... 879 Measuring the front brake disc lateral runout.......................................................................... 879 Measuring the brake disc thickness tolerance....................................................................... 880 46 50 19Removing and installing the front brake disc....................................................................... 881 Removal................................................................................................................ 881 Installation........................................................................................................... 881 46 53 02 Checking rear gray cast iron brake discs (wear assessment)........................................................1402 General................................................................................................................1402 1. Visual inspection for cracks and evaluating cracks..................................................................1402 Evaluating the cracks on the gray cast iron brake discs............................................................1403 2. Checking brake discs for minimum thickness..........................................................................1404 Notes on bedding in the new brake pads.................................................................................1405 46 53 02 Checking rear PCCB brake discs (wear assessment)..................................................................1406 General................................................................................................................1406 1. Visual inspection of the surfaces of the brake disc friction surfaces...............................................1406 PCCB brake disc wear appearance....................................................................................1407 2. Checking brake discs for minimum thickness..........................................................................1408 3. Checking brake discs for edge damage................................................................................1408 Note concerning bores (perforations) in the brake disc friction surface................................................1409 Note on bedding in the new brake pads..................................................................................1409 46 53 04 Measuring rear brake discs........................................................................................ 883 Measuring the rear brake disc lateral runout........................................................................... 883 Measuring the brake disc thickness tolerance....................................................................... 884 46 53 19 Removing and installing the rear brake disc....................................................................... 885 Removal................................................................................................................ 885 Installation........................................................................................................... 885 46 83 16 Adjusting the parking brake shoes................................................................................. 887 Check the free play of the parking brake lever......................................................................... 887 Adjusting the parking brake............................................................................................ 887 46 83 19 Removing and installing the parking brake shoes................................................................... 889 Removal................................................................................................................ 889 Installation........................................................................................................... 889 GT2 SPECIAL SECTION........................................................................................................ 0 46 Technical data/Brake wear limit - GT2...............................................................................1898 Technical Data - GT2...............................................................................................1898 Wear limit technical Data - GT2....................................................................................1899 46 16 24 Installing air ducts for PCCB brake discs - GT2...............................................................1975 Installing front air ducts.........................................................................................1975 Installing rear air ducts..........................................................................................1976 46 36 20 Removing and installing the front disc brake pads - GT2 / Turbo with PCCB.....................................1977 Removal............................................................................................................1978 Installation.......................................................................................................1980 Bedding in the brake pads......................................................................................1981 46 38 20 Removing and installing the rear disc brake pads - GT2 / Turbo with PCCB......................................1982 Removal............................................................................................................1983 Installation.......................................................................................................1984 Bedding in the brake pads......................................................................................1985 46 50 19 Removing and installing the front PCCB brake disc.............................................................1986 Removal............................................................................................................1986 Explanation of 2-part brake disc...................................................................................1987 Installation.......................................................................................................1987 Note on bedding in the new brake pads..........................................................................1988 46 53 19 Removing and installing the rear PCCB brake disc..............................................................1989 Removal............................................................................................................1989 Explanation of 2-part brake disc...................................................................................1990 Installation.......................................................................................................1990 Note on bedding in the new brake pads..........................................................................1991 47 BRAKES HYDRAULIC............................................................................................................ 0 47 Tightening torques for brake hydraulics................................................................................. 365 47 01 07 Bleeding brakes (vehicle with PSM)................................................................................ 892 PSM.................................................................................................................... 892 Procedure for bleeding................................................................................................. 892 1st step: Bleed brakes as usual........................................................................................ 892 2nd step: Bleeding at front on right with running booster pump......................................................... 893 47 01 07 Bleeding brake - GT2..............................................................................................1992 General................................................................................................................1992 Bleeding brakes........................................................................................................1992 47 08 55 Changing brake fluid.............................................................................................. 895 Procedure for changing brake fluid..................................................................................... 895 47 15 19 Removing and installing brake master cylinder..................................................................... 897 Removal................................................................................................................ 897 Installation........................................................................................................... 898 47 70 19 Removing and installing brake booster............................................................................. 900 Removal................................................................................................................ 900 Installation........................................................................................................... 902 STEERING....................................................................................................................... 0 48 Tightening torques for steering......................................................................................... 366 48 Test and assembly work on power steering................................................................................ 367 General................................................................................................................ 367 Checking hydraulic fluid of power steering and servo clutch............................................................ 367 Bleeding the steering system........................................................................................... 368 48 Assessment of steering gear after accident damage....................................................................... 370 Fundamentals........................................................................................................... 370 Assessment of the steering of a vehicle involved in an accident.................................................... 370 Exceptional regulation / order handling............................................................................ 371 48 10 19 Removing and installing steering wheel............................................................................ 907 Removal................................................................................................................ 907 Installation........................................................................................................... 908 48 90 19 Removing and installing steering gear............................................................................. 909 Removal................................................................................................................ 909 Installation........................................................................................................... 910 Notes for sliding piece and airbag contact unit.................................................................... 911 GROUP 5 BODY....................................................................................................................... 0 5 TECHNICAL NOTES.............................................................................................................. 0 Seam seals................................................................................................................. 227 Accessories............................................................................................................ 227 Front lid.......................................................................................................... 228 Door............................................................................................................... 228 Sliding roof panel................................................................................................. 229 5 Plug location plan....................................................................................................... 222 Top of front end....................................................................................................... 222 Bottom of front end.................................................................................................... 223 Side of front end...................................................................................................... 223 Bottom of lower side member and floor.................................................................................. 224 Top of lower side member and floor..................................................................................... 224 Bottom of rear end..................................................................................................... 225 Top of rear end........................................................................................................ 225 Side of rear end....................................................................................................... 226 5 Work sequence for accident repair........................................................................................ 230 5 Work sequence for determining scope of damaged vehicles involved in an accident.......................................... 232 5 Corrosion protection measures during repairs............................................................................. 234 Measures for maintaining long-term body protection..................................................................... 234 Prerequisite for ensuring vailidity of the long-life guarantee......................................................... 234 5 Vehicle identification number............................................................................................ 235 Imprinting new vehicle identification number........................................................................... 235 Materials, tools....................................................................................................... 236 5 Change identification data plate......................................................................................... 237 5 Undersealing............................................................................................................. 239 Overview diagram, lower front of vehicle............................................................................... 239 Overview diagram, bottom of lower side member and floor................................................................ 240 Overview diagram, lower rear end....................................................................................... 241 Tools and materials.................................................................................................... 241 5 Water drainage plan...................................................................................................... 261 5 Water drainage plan Cabriolet.......................................................................................... 242 5 Check dimensions for body repair - Cabriolet structure................................................................... 243 Structure dimensions for cabriolet..................................................................................... 243 5 Safety notes............................................................................................................. 246 Safety instructions for raising vehicles............................................................................... 246 Danger of injury when raising vehicles............................................................................. 246 Damage when raising vehicles....................................................................................... 246 Safety instructions for welding........................................................................................ 247 Dangers of injury when welding..................................................................................... 247 Safety instructions for flying sparks during grinding and welding work............................................. 247 Safety instructions for fuel tank.................................................................................. 248 Safety instructions for air conditioning........................................................................... 248 Safety instructions for sticking....................................................................................... 248 Safety instructions for Teromix-6700 two-component adhesive........................................................ 248 Safety instructions for installation work.............................................................................. 249 Safety instructions for sharp-edged body and unit parts............................................................ 249 Safety instructions for airbag system.............................................................................. 249 Safety instructions for door....................................................................................... 249 Safety instructions for corrosion protection........................................................................... 250 Safety instructions for plug location plan (body).................................................................. 250 Safety instructions for water drains (body)........................................................................ 250 5 General information and quality notes.................................................................................... 251 Measures for maintaining long-term body protection..................................................................... 251 Prerequisite for maintaining the long-life guarantee............................................................... 251 Electronic control modules............................................................................................. 251 Protection against overvoltage..................................................................................... 252 Replacing control modules.......................................................................................... 252 5 Tools and metalworking tools for body repairs............................................................................ 253 Straightening systems.................................................................................................. 253 Metalworking tools..................................................................................................... 253 Electrical equipment............................................................................................... 253 Mechanical equipment............................................................................................... 254 Compressed-air equipment........................................................................................... 254 Welding equipment.................................................................................................. 255 5 Diagram - keys to symbols for welding work............................................................................... 256 Resistance spot welding................................................................................................ 256 Inert-gas arc welding (MAG procedure).................................................................................. 256 Gas welding............................................................................................................ 256 5 Check dimensions for body repair......................................................................................... 258 Floorpan check dimensions.............................................................................................. 258 5 Diagram - body gap dimensions............................................................................................ 262 Gap dimensions, body front............................................................................................. 262 Gap dimensions, body centre............................................................................................ 264 Gap dimensions, body rear.............................................................................................. 265 Gap dimensions, body rear Carrera 4S................................................................................. 267 Diagram - Gap dimensions, Cabriolet.................................................................................... 269 Diagram - Centre gap dimensions, Cabriolet......................................................................... 269 Diagram - Gap dimensions, rear Cabriolet........................................................................... 271 Diagram, gap dimensions, Cabriolet rear - Carrera 4S............................................................... 272 Diagram - Gap dimensions, hardtop.................................................................................. 273 5 Body parts of high-strength steel........................................................................................ 275 High-strength steel plates............................................................................................. 276 Tailored blanks........................................................................................................ 277 Baked hardening........................................................................................................ 278 Straightening body parts............................................................................................... 278 Welding work........................................................................................................... 279 Reshaping.............................................................................................................. 279 Separation points...................................................................................................... 279 Diagram - Body, model year 2002........................................................................................ 280 Structural body parts (model care) for model year 2002............................................................. 280 50 FRONT....................................................................................................................... 0 50 10 55 Replacing closing panel...........................................................................................1410 Cutting out closing panel and front floor panel........................................................................1410 Preparing closing panel and front floor panel for installation and fitting.............................................1412 Welding in closing panel and front floor panel.........................................................................1414 Tools and materials....................................................................................................1415 50 14 55 Replacing front wall..............................................................................................1416 Cutting out front wall.................................................................................................1416 Preparing front wall for installation and fitting......................................................................1418 Welding in front wall..................................................................................................1420 Tools and materials....................................................................................................1421 50 30 19 Removing and installing air guide GT2...........................................................................2019 Removing and installing air guide......................................................................................2019 50 55 19 Removing and installing the wing.................................................................................. 913 50 56 19 Removing and installing wheel housing liners, front............................................................... 917 50 74 55 Replacing wheel housing...........................................................................................1422 Removing wheel housing, lower shell and outer side member from the body................................................1422 Preparing wheel housing, lower shell and outer side member for installation and fitting................................1424 Welding wheel housing, lower shell and outer side members into the body................................................1426 Tools and materials....................................................................................................1427 50 74 56 Replacing wheel housings and side members (sectional repair)......................................................1428 Cutting out wheel housings and side members............................................................................1428 Preparing wheel housings and side members for installation and fitting.................................................1430 Welding in wheel housings and side members.............................................................................1432 Materials and tools....................................................................................................1433 50 79 55 Replacing front inner side member.................................................................................1435 Removing front inner side member.......................................................................................1435 Preparing and fitting the front inner side member for installation.....................................................1437 Welding in front inner side member.....................................................................................1439 Materials, tools.......................................................................................................1440 50 93 30 Cleaning front water drains on Coupé and Cabriolet................................................................1442 Cleaning front water drains on Coupé and Cabriolet.....................................................................1442 51 CENTRE, ROOF, FRAME......................................................................................................... 0 51 03 55 Replacing roof....................................................................................................1445 Removing roof..........................................................................................................1445 Preparation of roof for installation and fitting.......................................................................1447 Welding in roof........................................................................................................1449 Tools and materials....................................................................................................1450 51 21 55 Replacing rear centre panel.......................................................................................1452 Removing rear centre panel.............................................................................................1452 Preparing the rear centre panel for installation and fitting...........................................................1454 Welding in the rear centre panel.......................................................................................1455 Tools and materials....................................................................................................1456 51 45 55 Replacing lower side member.......................................................................................1458 Cutting out lower side member..........................................................................................1458 Preparation for installation of lower side member and fitting..........................................................1460 Welding in lower side member...........................................................................................1462 Tools and materials....................................................................................................1463 51 45 55 Replacing lower side member - Cabriolet...........................................................................1464 Cutting out lower side member..........................................................................................1464 Preparation for installation of lower side member and fitting..........................................................1466 Welding in lower side member...........................................................................................1468 Tools and materials....................................................................................................1469 51 63 19 Removing and installing deformation element.......................................................................1470 Removing deformation element...........................................................................................1470 Installing deformation element.........................................................................................1471 51 87 55 Replacing seat cross member.......................................................................................1472 Cutting out seat cross member..........................................................................................1472 Preparation of seat cross member for installation and fitting..........................................................1474 Welding in seat cross member...........................................................................................1476 Tools and materials....................................................................................................1477 51 90 19 Removing and installing underside panel...........................................................................1478 Removing and installing front cover....................................................................................1478 Removing and installing middle cover...................................................................................1480 Removing and installing rear trim......................................................................................1481 53 REAR........................................................................................................................ 0 53 05 55 Replacing rear closing panel......................................................................................1482 Cutting out rear closing panel.........................................................................................1482 Preparing the rear closing panel for installation and fitting..........................................................1484 Welding in rear closing panel..........................................................................................1485 Tools and materials....................................................................................................1487 53 05 55 Replacing rear closing panel - Carrera 4S.........................................................................2069 Cutting out rear closing panel.........................................................................................2069 Inserting rear closing panel...........................................................................................2071 Tools and materials....................................................................................................2073 53 55 55 Replacing side section............................................................................................1488 Cutting through side section...........................................................................................1488 Preparing side section for installation and fitting....................................................................1491 Welding in the side section............................................................................................1493 Flanging the wheel arch edges GT2....................................................................................1496 Tools and materials....................................................................................................1496 53 69 19 Removing and installing wheel housing liners, rear................................................................ 919 53 69 19 Removing and installing rear wheel housing liners - Carrera 4S....................................................2075 55 90 19 Removing and installing rear lid - Carrera 4S.....................................................................2077 55 90 37 Disassembling and assembling rear lid Carrera 4S................................................................2079 Disassembling rear lid.................................................................................................2080 Assembling rear lid....................................................................................................2082 Removing and installing additional brake light.........................................................................2085 Installing rubber covering - Cabriolet.................................................................................2086 Removing and installing reflector cover................................................................................2087 Removing and installing wiring harness.................................................................................2087 Replacing the model logo...............................................................................................2088 Test and adjustment values.............................................................................................2088 Tightening torques.....................................................................................................2089 Materials and tools....................................................................................................2089 53 93 30 Cleaning rear water drains on Coupe and Cabriolet.................................................................1498 Cleaning rear water drains on Coupe and Cabriolet......................................................................1498 55 LIDS........................................................................................................................ 0 55 10 37 Disassembling and assembling release for front lid................................................................ 921 Disassembling release for front cover.................................................................................. 921 Assembling release for front cover..................................................................................... 923 Removing and installing support for cap release.................................................................... 924 Removing and installing support for cap release........................................................................ 924 55 17 19 Removing and installing front lower part of lid lock.............................................................. 926 Removing and installing bowden cable for lock actuation................................................................ 928 55 22 19 Removing and installing front lid................................................................................. 931 55 22 37 Disassembling and assembling front lid............................................................................ 933 55 25 19 Removing and installing front lid hinge........................................................................... 936 55 37 19 Removing and installing filler flap............................................................................... 938 55 57 37 Disassembling and assembling release for rear lid................................................................. 941 Disassembling release for rear lid..................................................................................... 941 Assembling release for rear lid........................................................................................ 943 55 62 19 Removing and installing front emergency release - as of MY 2003...................................................1501 Checking inner release of luggage compartment (Trunk Entrapment).......................................................1503 55 84 19 Removing and installing engine cover release......................................................................1504 Checking inner release of luggage compartment (Trunk Entrapment).......................................................1504 Removing engine cover release..........................................................................................1504 Installing engine cover release........................................................................................1505 55 86 19 Removing and installing lower part of lid lock.................................................................... 945 55 90 19 Removing and installing rear lid.................................................................................. 948 55 90 19 Removing and installing rear lid - GT2............................................................................2021 Removing and installing rear lid.......................................................................................2021 55 90 37 Disassembling and assembling rear lid............................................................................. 950 Disassembling rear lid................................................................................................. 950 Assembling rear lid.................................................................................................... 953 Replacing the model logo............................................................................................... 956 55 90 37 Disassembling and assembling rear lid GT2.......................................................................2024 Disassembling rear lid.................................................................................................2024 Assembling rear lid....................................................................................................2027 Replace model logo.................................................................................................2029 Removing and installing rear-lid wiring harness....................................................................2029 55 91 19 Removing and installing lid hinge................................................................................. 957 55 91 19 Removing and installing rear lid hinges - Carrera 4S..............................................................2090 57 DOORS,CENTRAL LOCKING....................................................................................................... 0 57 11 37 Disassembling and assembling door handle.......................................................................... 960 57 37 19 Removing and installing inner door release (bowden cable) for door lock........................................... 963 57 45 19 Removing and installing door handle............................................................................... 966 Removing and installing orientation lighting (LED light-emitting diodes)............................................... 968 Removing orientation lighting (LED light-emitting diodes).......................................................... 968 Installing orientation lighting (LED light-emitting diodes)........................................................ 969 57 51 16 Setting the door..................................................................................................1507 57 51 19 Removing and installing door......................................................................................1509 57 51 37 Disassembling and assembling door.................................................................................1513 Disassembling door.....................................................................................................1513 Assembling door........................................................................................................1519 57 51 37 Disassembling and assembling door.................................................................................1525 Diagram: sheetmetal clips and grommets.................................................................................1525 Basic setting of door lock.............................................................................................1526 Basic setting of the door lock before installation.................................................................1527 Standardising the system...............................................................................................1528 Standardising the power windows....................................................................................1528 Blockage detection function........................................................................................1528 Precondition for operation of the power windows....................................................................1528 Fitting the door window in the clamping jaws...........................................................................1528 Adjusting the door window angle in the vehicle's longitudinal direction................................................1529 Adjusting the door window height.......................................................................................1529 Adjustment procedure:..............................................................................................1530 Checking the adjustment............................................................................................1530 Adjustment of the door window pressing force on the door seal at the top and sides.....................................1530 Adjustment procedure:..............................................................................................1531 Checking the adjustment:...........................................................................................1531 Adjusting the lower stop of the power window unit......................................................................1531 GROUP 6 EXTERIOR EQUIPMENT......................................................................................................... 0 6 TECHNICAL NOTES.............................................................................................................. 0 6 Safety notes............................................................................................................. 282 Safety instructions for work on car windows............................................................................ 282 Danger of injury when working on car windows....................................................................... 282 Material damage when removing the glass from car windows........................................................... 282 Material damage when inserting the glass into car windows.......................................................... 282 Safety instructions for installation work.............................................................................. 283 Safety instructions for airbag system.............................................................................. 283 Safety instructions for sliding roof............................................................................... 283 Safety instructions for rear spoiler............................................................................... 283 Safety instructions for the pump unit hydraulic system of the rear spoiler......................................... 284 6 General information on installing and removing car windows............................................................... 285 Removing glass with cutting wire separator............................................................................. 285 Cutting power when removing glass with cutting thread.............................................................. 292 6 Overview of exterior colours............................................................................................. 294 Exterior paintwork solid............................................................................................. 294 Exterior paintwork metallic/pearl.................................................................................... 294 Special colours........................................................................................................ 295 6 Processing of Porsche 2-component window bonding agents.................................................................. 297 Overview of tools and materials........................................................................................ 297 Preparing the adhesive surfaces........................................................................................ 298 Combined procedure (handling double cartridge press)................................................................... 299 60 SLIDING ROOF................................................................................................................ 0 60 14 15 Re-teaching the lifting/sliding roof drive........................................................................ 971 60 14 19 Removing and installing lifting/sliding roof drive................................................................ 972 Removing lifting/sliding roof drive.................................................................................... 972 Installing lifting/sliding roof drive.................................................................................. 973 Emergency operation on lifting/sliding roof drive...................................................................... 974 60 28 19 Removing and installing frame for sliding roof.................................................................... 975 Removing frame for sliding roof........................................................................................ 975 Installing frame for sliding roof...................................................................................... 977 Tightening torques................................................................................................. 979 60 28 37 Disassembling and assembling frame for sliding roof............................................................... 980 Disassembling frame for sliding roof................................................................................... 980 Assembling frame for sliding roof...................................................................................... 982 60 40 19 Removing and installing sliding roof panel........................................................................ 984 Additional instructions for removing the inner panels.................................................................. 987 Additional instructions for fitting the inner panels................................................................... 988 61 CONVERTIBLE TOP, HARDTOP.................................................................................................... 0 63 BUMPERS..................................................................................................................... 0 63 10 19 Removing and installing front bumper.............................................................................. 990 Removing and installing front bumper................................................................................... 990 63 15 19 Removing and installing front spoiler............................................................................. 993 Removing front spoiler................................................................................................. 993 Installing front spoiler............................................................................................... 995 63 15 19 Removing and installing front spoiler GT2.......................................................................2032 Removing front spoiler.................................................................................................2032 Installing front spoiler...............................................................................................2034 63 15 37 Disassembling and assembling front spoiler........................................................................ 997 Disassembling front spoiler............................................................................................ 998 Removing front spoiler............................................................................................. 999 Assembling front spoiler...............................................................................................1000 Installing front spoiler...........................................................................................1002 63 15 37 Disassembling and assembling front spoiler GT2..................................................................2036 Disassembling front spoiler............................................................................................2036 Removing front spoiler.............................................................................................2038 Installing front spoiler...............................................................................................2039 Installing front spoiler...........................................................................................2040 63 50 19 Removing and installing rear bumper...............................................................................1004 Removing rear bumper...................................................................................................1004 Installing rear bumper.................................................................................................1006 Additional assembly instructions for installation of the bumper........................................................1008 Adjustment dimensions of the bumper................................................................................1008 Correct assembly of the heat shields...............................................................................1009 Additional assembly instructions for installation of the bumper - Carrera 4S...........................................1010 Correct assembly of the heat shields...............................................................................1010 Removing and installing frame with heat shield.....................................................................1011 Tightening torques.....................................................................................................1012 63 55 19 Removing and installing rear spoiler..............................................................................1013 Removing rear spoiler..................................................................................................1013 Install rear spoiler...................................................................................................1015 63 55 37 Disassembling and assembling rear spoiler.........................................................................1017 Disassembling rear spoiler.............................................................................................1017 Assembling rear spoiler................................................................................................1019 Additional instructions for replacing the rear spoiler.................................................................1021 64 GLASS, WINDOW CONTROL....................................................................................................... 0 64 12 19 Removing and installing windscreen................................................................................1533 Removing windscreen....................................................................................................1533 Preparing the window section for installation..........................................................................1535 Preparing the windscreen for installation..............................................................................1536 Fitting windscreen.....................................................................................................1538 Overview of tools and materials........................................................................................1541 64 54 19 Removing and installing power window motor........................................................................1544 Removing power window motor............................................................................................1544 Installing power window motor..........................................................................................1544 Standardising the new power window motor...............................................................................1545 Tightening torques.....................................................................................................1545 64 71 19 Removing and installing rear power windows (Cabriolet)............................................................1546 Removing rear power windows (Cabriolet)................................................................................1547 Installing rear power windows (Cabriolet)..............................................................................1548 Additional instructions for adjusting or replacing the rear power window...............................................1550 Tools and materials....................................................................................................1551 Tightening torques.....................................................................................................1551 Test and adjusting values..............................................................................................1551 64 75 19 Removing and installing side window...............................................................................1552 Removing side window...................................................................................................1552 Installing side window.................................................................................................1554 Test and adjusting values..............................................................................................1555 Tightening torques.....................................................................................................1555 64 75 19 Removing and installing rear side window (Cabriolet)..............................................................1556 Removing side window...................................................................................................1556 Installing side window.................................................................................................1556 Tightening torques.....................................................................................................1557 Test and adjusting values..............................................................................................1557 64 76 19 Removing and installing side window seal..........................................................................1558 Removing side window seal..............................................................................................1558 Removing the retaining strip.......................................................................................1560 Installing side window seal............................................................................................1560 Installing the retaining strip.....................................................................................1562 Materials and tools....................................................................................................1562 64 76 19 Removing and installing rear side window seal (Cabriolet).........................................................1563 Removing side window seal..............................................................................................1563 Installing side window seal............................................................................................1563 64 86 01 Checking function of heating for rear window......................................................................1023 Check with the temperature probe.......................................................................................1023 64 86 19 Removing and installing rear window...............................................................................1024 Removing rear window...................................................................................................1024 Preparing the window section for installation..........................................................................1026 Installing rear window.................................................................................................1027 Overview of tools and materials........................................................................................1030 64 86 19 Removing and installing rear glass window of Cabriolet............................................................1564 Removing rear glass window of Cabriolet................................................................................1564 Installing rear glass window of Cabriolet..............................................................................1566 Tools and materials....................................................................................................1568 Use of the circlip pliers..........................................................................................1568 64 86 19 Removing and installing rear window (hardtop).....................................................................1570 Removing rear window (hardtop).........................................................................................1571 Preparing the window section (hardtop) for installation................................................................1573 Preparing the rear window (hardtop) for installation...................................................................1575 Installing rear window (hardtop).......................................................................................1576 Overview of tools and materials........................................................................................1579 Tightening torques.....................................................................................................1580 66 EXTERIOR EQUIPMENT.......................................................................................................... 0 66 13 19 Removing and installing air inlet.................................................................................1032 Removing air inlet.....................................................................................................1032 Installing air inlet...................................................................................................1033 66 31 19 Removing and installing sill cover................................................................................1582 Removing sill cover....................................................................................................1582 Installing sill cover..................................................................................................1584 66 36 19 Removing and installing roof joint strip..........................................................................1036 Removing roof joint strip..............................................................................................1036 Installing roof joint strip............................................................................................1038 66 58 19 Removing and installing rear spoiler..............................................................................1040 Removing rear spoiler..................................................................................................1040 Installing rear spoiler................................................................................................1042 66 58 19 Removing and installing rear spoiler GT2........................................................................2042 Removing rear spoiler..................................................................................................2042 Installing rear spoiler................................................................................................2044 Replacing rear spoiler fork........................................................................................2045 66 72 Assignment of spoiler drive, relays and instrument cluster........................................................... 421 Variants of the spoiler drive.......................................................................................... 421 66 72 37 Disassembling and assembling pump unit............................................................................1586 Removing hydraulic cylinder............................................................................................1587 Filling the hydraulic cylinder.........................................................................................1589 Installing hydraulic cylinder..........................................................................................1589 Removing pump..........................................................................................................1591 Filling the pump unit..................................................................................................1592 Installing pump........................................................................................................1592 Bleeding the pump unit.................................................................................................1594 Removing and installing wiring harness.................................................................................1596 Removing wiring harness............................................................................................1596 Installing wiring harness..........................................................................................1597 Removing and installing micro switches for rear spoiler............................................................1599 Removing micro switches............................................................................................1599 Installing micro switches..........................................................................................1600 Troubleshooting........................................................................................................1600 Tools and materials....................................................................................................1601 66 78 01 Checking function of heating for mirror glass.....................................................................1045 Check with the temperature probe.......................................................................................1045 66 85 19 Removing and installing micro switches for rear spoiler...........................................................1602 Remove micro switches..................................................................................................1602 Installing micro switches..............................................................................................1603 Tools..................................................................................................................1603 66 89 19 Removing and installing rearview mirror...........................................................................1046 Removing the rearview mirror...........................................................................................1046 Installing the rearview mirror.........................................................................................1048 66 89 37 Disassembling and assembling the rearview mirror..................................................................1604 Disassembling the rearview mirror......................................................................................1604 Assembling the rearview mirror.........................................................................................1606 68 INTERIOR EQUIPMENT.......................................................................................................... 0 68 05 19 Removing and installing inner sill (driver's side)................................................................1609 Removing inner sill....................................................................................................1609 Installing inner sill..................................................................................................1611 68 05 19 Removing and installing inner sill (passenger's side).............................................................1613 Removing inner sill....................................................................................................1613 Installing inner sill..................................................................................................1614 68 11 19 Removing and installing glove compartment lock....................................................................1616 Removing and installing glove compartment lock.........................................................................1616 68 12 19 Removing and installing lid for glove compartment.................................................................1618 Removing lid for glove compartment.....................................................................................1618 Installing lid for glove compartment...................................................................................1619 Replacing microswitch and interior light...............................................................................1620 Replacing pneumatic shock absorber.....................................................................................1621 68 15 19 Removing and installing glove compartment.........................................................................1623 Removing glove compartment.............................................................................................1623 Installing glove compartment...........................................................................................1625 68 17 19 Removing and installing center console (front section)............................................................1627 68 17 19 Removing and installing center console............................................................................1631 68 17 37 Disassembling and assembling centre console.......................................................................1050 Disassembling and assembling cover for the oddments tray...............................................................1052 68 23 19 Removing and installing sun visors................................................................................1054 Removing sun visors....................................................................................................1054 Installing sun visors..................................................................................................1055 68 23 37 Disassembling and assembling sun visor............................................................................1056 Disassembling sun visor................................................................................................1056 Assembling sun visor...................................................................................................1058 68 27 13 Bonding on the interior rearview mirror...........................................................................1060 Bonding the assembled interior mirror onto the windscreen..............................................................1060 68 27 19 Removing and installing the interior rearview mirror..............................................................1063 Removing the interior rearview mirror..................................................................................1063 Installing the interior rearview mirror................................................................................1065 68 30 19 Removing and installing cup holder................................................................................1634 Removing cup holder....................................................................................................1634 Installing cup holder..................................................................................................1635 69 PASSENGER PROTECTION........................................................................................................ 0 69 Safety regulations for vehicles with airbag and belt tensioner.......................................................... 372 Assembly and adjustment work........................................................................................... 373 Handling airbag and belt tensioner..................................................................................... 374 Dangers for persons and the environment............................................................................ 374 Protective measures and rules of behaviour......................................................................... 374 Behaviour in cases of malfunction or danger........................................................................ 375 Materials.......................................................................................................... 376 General information.................................................................................................... 376 Component exchange after airbag triggering......................................................................... 377 After triggering of the side airbag unit........................................................................... 377 After triggering of belt tensioner................................................................................. 377 69 11 01 Checking seat belts...............................................................................................1644 Checking belt strap....................................................................................................1644 Checking automatic belt device (locking effect)........................................................................1645 Belt buckle, visual inspection.........................................................................................1646 Belt buckle, function test.............................................................................................1646 Checking sash guides...................................................................................................1647 Checking mounting elements and mounting points.........................................................................1647 69 11 19 Removing and installing front three-point belt....................................................................1636 Removing front three-point belt........................................................................................1636 Installing front three-point belt......................................................................................1638 69 11 19 Removing and installing front three-point belt - Cabriolet........................................................1640 Removing front three-point belt........................................................................................1640 Installing front three-point belt......................................................................................1642 69 12 19 Removing and installing rear three-point belt.....................................................................1648 Removing rear three-point belt.........................................................................................1648 Installing rear three-point belt.......................................................................................1650 69 12 19 Removing and installing rear three-point belt - Cabriolet.........................................................1652 Removing rear three-point belt.........................................................................................1652 Installing rear three-point belt.......................................................................................1654 69 13 19 Removing and installing belt tensioner - as of MY 2002............................................................1656 Removing belt tensioner................................................................................................1656 Installing belt tensioner..............................................................................................1657 69 36 19 Removing and installing adjustment fitting (seat belt height adjuster)............................................1659 Removing and installing adjustment fitting.............................................................................1659 69 51 19 Removing and installing sensor for side airbag....................................................................1661 Remove sensor for side airbag..........................................................................................1661 Install sensor for side airbag.........................................................................................1663 Tools..................................................................................................................1664 69 53 19 Removing and installing the triggering unit for the airbag........................................................1067 Removing triggering unit for airbag....................................................................................1067 Installing triggering unit for airbag..................................................................................1068 69 54 19 Removing and installing the contact unit..........................................................................1069 Installing contact unit................................................................................................1069 Installing contact unit................................................................................................1069 69 58 19 Removing and installing the driver's airbag unit..................................................................1071 Removing driver's airbag unit..........................................................................................1071 Installing driver's airbag unit........................................................................................1071 69 59 Disposal of airbag and belt tensioner units.......................................................................... 422 Safety measures when igniting airbag units............................................................................. 422 Tools.................................................................................................................. 423 Connecting ignition tool............................................................................................... 424 Driver's side...................................................................................................... 424 Passenger's side................................................................................................... 424 Side airbag........................................................................................................ 424 Belt tensioner..................................................................................................... 425 Ignition............................................................................................................... 425 69 59 19 Removing and installing the passenger's airbag unit...............................................................1073 Removing passenger's airbag unit.......................................................................................1073 Installing passengers airbag unit.....................................................................................1074 69 63 19 Removing and installing the side airbag unit......................................................................1075 Removing side airbag unit..............................................................................................1075 Installing side airbag unit............................................................................................1076 Removing sensor for side airbag unit...............................................................................1076 69 72 19 Removing and installing roll-over bar.............................................................................1665 Safety instructions for work on the roll-over protection system........................................................1665 Mechanical emergency triggering of the roll-over protection system.....................................................1666 Removing roll-over protection system...................................................................................1667 Installing roll-over protection system.................................................................................1668 Tightening torques.....................................................................................................1670 69 72 19 Removing and installing roll-over bar - GT2.......................................................................2047 Removing roll-over bar.................................................................................................2047 Installing the roll-over bar...........................................................................................2050 Adjusting the roll-over bar............................................................................................2054 Assembly instructions for the rear trim, the floor covering and the closure caps.......................................2054 69 74 19 Removing and installing control module for roll-over protection system............................................1671 Removing control module................................................................................................1671 Installing control module..............................................................................................1671 Tools and materials....................................................................................................1672 69 77 19 Removing and installing frame for roll-over protection system.....................................................1673 Removing and installing frame for roll-over protection system..........................................................1673 Tightening torques.....................................................................................................1675 GROUP 7 INTERIOR EQUIPMENT......................................................................................................... 0 7 TECHNICAL NOTES.............................................................................................................. 0 7 Special notes for the care of soft-look paint surfaces................................................................... 302 Light soiling (e.g. dust).............................................................................................. 302 Heavy soiling (e.g. oily, greasy dirt)................................................................................. 302 70 LININGS, INSULATION......................................................................................................... 0 70 05 19 Removing and installing front luggage compartment trim............................................................1676 Removing and installing trims units....................................................................................1676 Removing and installing carpet lining..................................................................................1678 Tools and materials....................................................................................................1679 70 18 19 Removing and installing the instrument panel and instrument panel bracket.........................................1078 Removing and installing the instrument panel...........................................................................1078 Removing and installing the instrument panel bracket...................................................................1080 Tightening torque......................................................................................................1082 Tools and materials....................................................................................................1082 70 18 19 Removing and installing the instrument panel and instrument panel bracket - as of model year 2003.................1680 Removing and installing the instrument panel...........................................................................1681 Removing and installing the instrument panel bracket...................................................................1682 Tightening torque......................................................................................................1685 Tools and materials....................................................................................................1685 70 18 37 Disassembling and assembling the instrument panel.................................................................1084 Disassembling the instrument panel.....................................................................................1084 Removing the regulator for wiping interval.........................................................................1089 Removing the cigarette lighter.....................................................................................1089 Assembling the instrument panel........................................................................................1090 Installing the regulator for wiping interval.......................................................................1095 Installing the cigarette lighter...................................................................................1095 Additional assembly notes for the cover and center nozzle for the instrument panel as of model year 2002.............1096 Removing cover and center nozzle for the instrument panel..........................................................1096 Removing holder....................................................................................................1097 Installing holder..................................................................................................1097 Installing cover and center nozzle for the instrument panel........................................................1098 70 22 19 Removing and installing cowl panel cover..........................................................................1100 Removing and installing cowl panel cover...............................................................................1100 70 41 19 Removing and installing floor covering............................................................................1687 70 57 19 Removing and installing trim of A, B and C-pillars................................................................1690 Removing and installing trim of A, B and C-pillars.....................................................................1690 Installing trim of A, B and C-pillars..................................................................................1692 70 57 19 Removing and installing A-pillar trim Cabriolet.................................................................1694 Removing A-pillar trim.................................................................................................1694 Installing A-pillar trim...............................................................................................1695 Tightening torques.....................................................................................................1697 70 59 19 Removing and installing door trim panel...........................................................................1103 Removing door trim panel...............................................................................................1103 Installing door trim panel.............................................................................................1105 Installation note for door sealing film................................................................................1107 Installation note on door sealing film for vehicles without side airbag............................................1107 Notes on the installation of partly detached door sealing films....................................................1107 Fitting sliding strip on the inner door panel..........................................................................1108 Materials and tools....................................................................................................1109 Tightening torque......................................................................................................1109 70 65 19 Removing and installing oddments compartment lid..................................................................1110 Removing and installing oddments compartment lid.......................................................................1110 70 75 19 Removing and installing side-panel lining.........................................................................1698 Removing side-panel lining.............................................................................................1698 Installing side-panel lining...........................................................................................1700 70 75 19 Removing and installing side-panel lining Cabriolet.............................................................1702 Removing side-panel lining.............................................................................................1702 Installing side-panel lining...........................................................................................1704 70 84 19 Removing and installing roof lining...............................................................................1113 Removing roof lining...................................................................................................1113 Installing roof lining.................................................................................................1115 70 84 19 Removing and installing Cabriolet roof lining.....................................................................1706 Removing roof lining, front............................................................................................1707 Installing front roof lining...........................................................................................1710 Removing rear roof lining..............................................................................................1712 Installing rear roof lining............................................................................................1713 Removing and installing side roof lining...............................................................................1715 Removing side roof lining..........................................................................................1715 Installing side roof lining........................................................................................1716 Tightening torques.....................................................................................................1716 72 SEAT, FRAMES................................................................................................................ 0 72 01 19 Removing and installing front seat................................................................................1717 Removing front seat....................................................................................................1717 Installing front seat..................................................................................................1719 72 01 19 Removing and installing bucket seat GT2 - as of MY 2001.........................................................2056 Removing bucket seat GT2...............................................................................................2056 Installing bucket seat GT2.............................................................................................2058 Fitting six-point seat belt GT2..................................................................................2059 72 21 19 Removing and installing cushion carrier...........................................................................1721 Removing front cushion carrier.........................................................................................1721 Installing front cushion carrier.......................................................................................1723 72 36 19 Removing and installing motor for the lumbar support..............................................................1725 Removing lumbar adjustment device for the lumbar support...............................................................1726 Removing motor for the lumbar support..................................................................................1727 Removing electrical line for the lumbar................................................................................1727 Removing lumbar support................................................................................................1727 Installling lumbar adjustment device for the lumbar support............................................................1728 Installing motor for the lumbar support................................................................................1729 Installing electrical line for the lumbar..............................................................................1729 Installing lumbar support..............................................................................................1729 Tools..................................................................................................................1730 Test plan for the lumbar adjustment device.............................................................................1730 72 86 19 Removing and installing switch for seat adjustment................................................................1731 Removing switch for seat adjustment....................................................................................1732 Installing switch for seat adjustment..................................................................................1733 72 87 19 Removing and installing electric motor for the seat adjustment....................................................1735 Removing electric motor for seat adjustment............................................................................1735 Installing electric motor for seat adjustment..........................................................................1737 Tools..................................................................................................................1738 Test plan for the seat adjustment......................................................................................1738 72 88 19 Removing and installing electric motor for the front seat height adjustment.......................................1740 Removing electric motor for front seat height adjustment...............................................................1740 Installing electric motor for front seat height adjustment.............................................................1742 Tools..................................................................................................................1743 Test plan for the front seat height adjustment.........................................................................1743 72 89 19 Removing and installing electric motor for the backrest adjustment................................................1745 Removing and installing electric motor for the backrest adjustment.....................................................1746 Installing electric motor for backrest adjustment......................................................................1747 Routing of wiring harness for the backrest adjustment..................................................................1748 Tools..................................................................................................................1748 Test plan for the backrest adjustment device...........................................................................1749 72 92 19 Removing and installing electric motor for the rear seat height adjustment........................................1750 Removing electric motor for rear seat height adjustment................................................................1750 Installing electric motor for rear seat height adjustment..............................................................1752 Tools..................................................................................................................1753 Test plan for the rear seat height adjustment..........................................................................1753 74 SEAT UPHOLSTERIES, COVER.................................................................................................... 0 74 13 55 Replacing cover for front seat cushion............................................................................1755 Removing cover for the front seat......................................................................................1755 Installing cover for the seat cushion..................................................................................1757 Tools and materials....................................................................................................1758 74 19 19 Removing and installing centre backrest strip.....................................................................1759 Removing the backrest centre strip.....................................................................................1759 Installing the backrest centre strip...................................................................................1761 74 19 55 Replacing covering for backrest centre strip......................................................................1762 Removing covering for backrest centre strip............................................................................1762 Installing covering for backrest centre strip..........................................................................1764 Tools and materials....................................................................................................1765 74 27 19 Removing and installing control module for seat heating...........................................................1766 Removing and installing control module for seat heating................................................................1767 Seat heating line route................................................................................................1767 Central plug...........................................................................................................1768 Removing and installing pin housing for seat heating and belt buckle...................................................1768 Tools..................................................................................................................1769 Test plan for the seat heating.........................................................................................1769 GROUP 8 AIR CONDITIONING........................................................................................................... 0 8 TECHNICAL DATA............................................................................................................... 0 8 Air conditioning......................................................................................................... 304 Technical data for the air-conditioning system......................................................................... 304 80 HEATING..................................................................................................................... 0 80 23 19 Removing and installing heat exchanger............................................................................1118 Removing heat exchanger................................................................................................1118 Installing heat exchanger..............................................................................................1118 85 VENTILATION................................................................................................................. 0 85 30 19 Removing and installing heater/fresh-air blower motor.............................................................1119 Removing heater/fresh-air blower motor.................................................................................1119 Installing heater/fresh-air blower motor...............................................................................1120 87 AIR CONDITIONING............................................................................................................ 0 87 Nominal values for pressures and temperatures........................................................................... 378 General test prerequisites............................................................................................. 378 Centre vent temperature as a function of ambient temperature....................................................... 378 High pressure in cold circuit as a function of ambient temperature................................................. 379 Low pressure in cold circuit as a function of ambient temperature.................................................. 379 87 01 19 Removing and installing the heating/air-conditioning unit.........................................................1121 Removing heating/air-conditioning unit.................................................................................1121 Installing heating/air-conditioning unit...............................................................................1123 87 02 19 Removing and installing the heating/air-conditioning control......................................................1125 Removing heating/air-conditioning control..............................................................................1125 Performing system test.................................................................................................1125 Tests..................................................................................................................1126 87 03 Safety regulations when handling refrigerant R134a................................................................... 427 87 03 17 Assembly work on the air-conditioning system......................................................................1127 Service unit SECU 134..................................................................................................1127 Assembly work involving the refrigerant system.........................................................................1129 General assembly sequence..............................................................................................1129 Removing refrigerant by suction and cleaning...........................................................................1130 Cleaning the refrigerant...............................................................................................1131 Draining off old refrigerant oil.......................................................................................1131 Evacuating.............................................................................................................1132 Topping up with new refrigerant oil....................................................................................1133 Filling via the high-pressure side.....................................................................................1133 Refilling the air-conditioning system..................................................................................1134 Distribution of the oil quantity in the refrigerant circuit............................................................1135 87 20 19 Removing and installing drive motors..............................................................................1136 Removing drive motors..................................................................................................1136 Removing drive motor for temperature valve and central valve.......................................................1136 Removing drive motor for footwell/defrost..........................................................................1137 Removing drive motor for fresh-air/recirculation valve.............................................................1137 Installing drive motors................................................................................................1137 Installing drive motor for temperature valve, central valve and footwell/defrost...................................1137 Installing drive motor for fresh-air/recirculation valve...........................................................1138 87 27 19 Removing and installing the magnetic coupling.....................................................................1139 Removing the magnetic coupling.........................................................................................1139 Installing the magnetic coupling.......................................................................................1139 Checking the air gap of the magnet coupling........................................................................1140 87 34 19 Removing and installing the compressor............................................................................1141 Removing the compressor................................................................................................1141 Installing the compressor..............................................................................................1142 Running-in regulations for new compressor..........................................................................1143 87 50 19 Removing and installing the condenser.............................................................................1144 Removing the condenser.................................................................................................1144 Installing the condenser...............................................................................................1144 87 53 19 Removing and installing fan for condenser.........................................................................1146 Removing fan for condenser.............................................................................................1146 Installing fan for condenser...........................................................................................1146 87 55 19 Removing and installing the fluid tank............................................................................1147 Removing fluid tank....................................................................................................1147 Installing fluid tank..................................................................................................1147 87 58 19 Removing and installing footwell blower outlet sensor.............................................................1148 Removing footwell blower outlet sensor.................................................................................1148 Installing footwell blower outlet sensor...............................................................................1148 87 59 19 Removing and installing outside temperature sensor................................................................1149 Removing outside temperature sensor....................................................................................1149 Installing outside temperature sensor..................................................................................1149 87 70 19 Removing and installing the expansion valve.......................................................................1150 Removing expansion valve...............................................................................................1150 Installing expansion valve.............................................................................................1150 87 78 19 Removing and installing blower driver.............................................................................1151 Removing blower driver.................................................................................................1151 Installing blower driver...............................................................................................1151 87 82 19 Removing and installing interior temperature sensor...............................................................1152 Removing interior temperature sensor...................................................................................1152 Installing interior temperature sensor.................................................................................1152 87 83 19 Removing and installing pressure switch for the air-conditioning system...........................................1153 Removing pressure switch for the air-conditioning system...............................................................1153 Installing pressure switch for the air-conditioning system.............................................................1153 GROUP 9 ELECTRICS.................................................................................................................. 0 9 TECHNICAL NOTES.............................................................................................................. 0 9 Work instructions after disconnecting the battery........................................................................ 305 Effect of disconnection or total discharge of the battery on electrical systems in the vehicle, subsequent measures.... 305 Control module memories................................................................................................ 305 Supply voltage fault entry............................................................................................. 306 Test drive after connecting the battery................................................................................ 306 2470 DME control module................................................................................................ 306 6452 Power windows..................................................................................................... 307 90 25 Instrument cluster............................................................................................... 307 9030 Clock............................................................................................................. 307 9023 Fuel level display................................................................................................ 307 9120 Radio............................................................................................................. 308 9110 PCM............................................................................................................... 308 90 INSTRUMENT, ALARM SYSTEM.................................................................................................... 0 90 12 15 Setting ahead the total mileage counter in the instrument cluster.................................................1154 Setting ahead with the Porsche System Tester 2.........................................................................1154 90 25 19 Removing and installing instrument cluster........................................................................1771 Removing instrument cluster............................................................................................1771 Installing instrument cluster..........................................................................................1772 Coding the instrument cluster..........................................................................................1772 90 25 37 Disassembling and assembling instrument cluster...................................................................1155 90 50 19 Removing and installing horn......................................................................................1156 Removing horn..........................................................................................................1156 Installing horn........................................................................................................1157 91 RADIO, TELEPHONE, NAVIGATION................................................................................................ 0 91 Retrofitting mobile communication systems............................................................................... 381 91 10 19 Removing and installing display and operator control unit (PCM)...................................................1774 Removing display and operator control unit (PCM).......................................................................1775 Installing display and operator control unit (PCM).....................................................................1775 Connecting and switching on the Porsche System Tester 2............................................................1775 Device code input..................................................................................................1776 91 10 19 Removing and installing display and operator control unit (PCM 2) - as of MY 2003.................................1777 Removing display and operator control unit (PCM 2).....................................................................1777 Installing display and operator control unit (PCM 2)...................................................................1778 Teaching display and operator control unit (PCM 2).....................................................................1780 91 12 15 Adjusting (calibrating) PCM navigation unit.......................................................................1158 GPS receiver...........................................................................................................1158 Distance sensor........................................................................................................1158 Gyroscope..............................................................................................................1159 Procedure after commissioning..........................................................................................1159 Procedure after changing a tyre........................................................................................1159 Procedure after the power supply has been interrupted..................................................................1159 91 12 19 Removing and installing navigation unit...........................................................................1160 Removing navigation unit...............................................................................................1160 Installing navigation unit.............................................................................................1160 Device code input..................................................................................................1160 91 13 19 Removing and installing GPS antenna...............................................................................1162 Removing GPS antenna...................................................................................................1162 Installing GPS antenna.................................................................................................1162 91 20 02 Checking complaints about car radio system........................................................................1784 Malfunctions in radio system...........................................................................................1784 Reduced sound quality in one or more loudspeakers......................................................................1785 Remedying problems with the amplifier..................................................................................1786 Interference noises....................................................................................................1787 Interference noises, checking cable connections....................................................................1788 Interference noises due to alternator..............................................................................1789 Interference noises due to engine..................................................................................1789 Interference noise due to antenna..................................................................................1790 Interference noises due to power supply............................................................................1791 Interference noises due to all looudspeakers.......................................................................1793 Electromagnetic compatibility (EMC) - Troubleshooting..................................................................1794 Tools..................................................................................................................1795 91 20 19 Removing and installing the car radio.............................................................................1164 Removing the car radio.................................................................................................1164 Installing the car radio...............................................................................................1164 Entering the code number...............................................................................................1165 91 24 19 Removing and installing the car radio - as of MY 2003.............................................................1796 Tools..................................................................................................................1796 Removing the car radio.................................................................................................1796 Installing the car radio...............................................................................................1798 Teaching the car radio.................................................................................................1798 91 42 19 Removing and installing rear loudspeakers, Bose sound package.....................................................1801 Removing rear loudspeakers.............................................................................................1801 Installing rear loudspeakers...........................................................................................1802 91 44 19 Removing and installing the loudspeaker amplifier.................................................................1804 Removing the loudspeaker amplifier.....................................................................................1804 Installing the loudspeaker amplifier...................................................................................1806 91 47 19 Removing and installing radio antenna.............................................................................1166 Removing radio antenna.................................................................................................1166 Installing radio antenna...............................................................................................1166 91 57 15 Setting hands-free microphone to the telephone type...............................................................1167 Setting................................................................................................................1167 91 57 19 Removing and installing hands-free microphone.....................................................................1168 Removing hands-free microphone.........................................................................................1168 Installing hands-free microphone.......................................................................................1169 91 74 19 Removing and installing control module for parking assistant......................................................1808 Removing control module for parking assistant..........................................................................1808 Installing control module for parking assistant........................................................................1809 91 75 19 Removing and installing sensor for ParkAssistent..................................................................1170 Removing sensor for ParkAssistent......................................................................................1170 Installing sensor for ParkAssistent....................................................................................1170 ParkAssistent control module...........................................................................................1171 91 84 19 Removing and installing antenna amplifier - as of MY 2003.........................................................1810 Removing antenna amplifier.............................................................................................1811 Installing antenna amplifier...........................................................................................1811 91 86 19 Removing and installing control module for antenna................................................................1812 Removing control module for antenna....................................................................................1812 Installing control module for antenna..................................................................................1813 91 90 19 Removing and installing control module for telephone..............................................................1815 Removing control module for telephone..................................................................................1815 Installing control module for telephone................................................................................1816 92 WINDSHIELD WIPERS, WASHERS.................................................................................................. 0 92 12 19 Removing and installing rain sensor...............................................................................1817 Removing rain sensor...................................................................................................1817 Installing rain sensor.................................................................................................1820 Open circuit in the rain sensor connection (emergency interval operation)..............................................1823 92 13 19 Removing and installing control module for rain sensor............................................................1824 Removing control module for rain sensor................................................................................1825 Installing control module for rain sensor..............................................................................1826 Safety function in the event of failure (engine blockage)..............................................................1827 92 15 19 Removing and installing the wiper motor...........................................................................1172 Removing wiper motor...................................................................................................1172 Installing wiper motor.................................................................................................1172 92 19 19 Removing and installing the wiper link............................................................................1174 Removing wiper link....................................................................................................1174 Installing wiper link..................................................................................................1174 92 27 19 Removing and installing the wiper blades..........................................................................1176 92 30 19 Removing and installing rear window wiper system..................................................................1177 Removing rear window wiper system......................................................................................1177 Installing rear window wiper system....................................................................................1177 92 56 19 Removing and installing pump for windscreen washer system.........................................................1178 Removing pump for windscreen washer system.............................................................................1178 Installing pump for windscreen washer system...........................................................................1178 92 60 19 Removing and installing tank for windscreen washer system.........................................................1179 Removing tank for windscreen washer system (7 litres)..................................................................1179 Removing tank for windscreen washer system (3 litres)..................................................................1179 Installing tank for windscreen washer system...........................................................................1180 92 66 Non-adjustable spray nozzles......................................................................................... 428 92 67 19 Removing and installing fluid level indicator.....................................................................1181 Removing fluid level indicator.........................................................................................1181 Installing fluid level indicator.......................................................................................1181 92 70 19 Removing and installing cover for spray nozzle....................................................................1182 Removing cover for spray nozzle........................................................................................1182 Installing cover for spray nozzle......................................................................................1182 92 72 19 Removing and installing spray nozzle for headlight washing system.................................................1183 Removing spray nozzle for headlight washing system.....................................................................1183 Installing spray nozzle for headlight washing system...................................................................1183 92 78 19 Removing and installing pump for headlight washing system.........................................................1184 Removing pump for headlight washing system.............................................................................1184 Installing pump for headlight washing system...........................................................................1184 94 EXTERIOR LIGHTS, SWITCHES................................................................................................... 0 94 05 19 Removing and installing main light switch.........................................................................1185 Removing main light switch.............................................................................................1185 Installing main light switch...........................................................................................1186 94 15 01 Troubleshooting on the Xenon headlight............................................................................1187 94 15 05 Main headlights - basic adjustment in the body....................................................................1188 Adjustment instructions................................................................................................1188 Adjustment procedure...................................................................................................1189 94 15 15 Left / right traffic conversion for Xenon headlights..............................................................1190 Converting Xenon headlights............................................................................................1190 Installation...........................................................................................................1190 94 15 19 Removing and installing the main headlights.......................................................................1192 94 23 Bulb table and installation instructions............................................................................. 429 Bulb table............................................................................................................. 429 Installing bulbs....................................................................................................... 429 94 23 19 Removing and installing gas discharge lamp (Xenon headlights).....................................................1193 Removing gas discharge lamp (Xenon headlights).........................................................................1193 Installing gas discharge lamp (Xenon headlights).......................................................................1193 94 27 19 Removing and installing bulb for parking light....................................................................1195 Removing bulb for parking light........................................................................................1195 Installing bulb for parking light......................................................................................1195 94 29 19 Removing and installing bulb for number plate light...............................................................1196 Removing bulb for number plate light...................................................................................1196 Installing bulb for number plate light.................................................................................1196 94 33 19 Removing and installing bulb for tail light.......................................................................1197 Removing bulb for tail light...........................................................................................1197 Installing bulb for tail light.........................................................................................1197 94 47 19 Removing and installing the hazard warning light switch...........................................................1198 Removing hazard warning light switch...................................................................................1198 Installing hazard warning light switch.................................................................................1198 94 53 19 Removing and installing bulb for side direction indicator light...................................................1199 Removing bulb for side direction indicator light.......................................................................1199 Installing bulb for side direction indicator light.....................................................................1199 94 56 19 Removing and installing bulb for direction indicator light........................................................ 130 Removing bulb for direction indicator light............................................................................ 130 Installing bulb for direction indicator light.......................................................................... 130 94 57 19 Removing and installing control module for gas discharge lamp.....................................................1200 Removing control module for gas discharge lamp.........................................................................1200 Installing control module for gas discharge lamp.......................................................................1201 94 66 19 Removing and installing bulb for auxiliary headlight (high beam headlight)........................................1202 Removing bulb for auxiliary headlight..................................................................................1202 Installing bulb for auxiliary headlight................................................................................1202 94 67 19 Removing and installing bulb for fog light........................................................................1203 Removing bulb for fog light............................................................................................1203 Installing bulb for fog light..........................................................................................1203 94 70 19 Removing and installing bulb for additional brake light...........................................................1204 Removing bulb for additional brake light...............................................................................1204 Installing bulb for additional brake light.............................................................................1204 94 78 19 Removing and installing front angle sensor for headlight beam adjustment..........................................1205 Removing front angle sensor for headlight beam adjustment..............................................................1205 Installing front angle sensor for headlight beam adjustment............................................................1205 94 79 19 Removing and installing rear angle sensor for headlight beam adjustment...........................................1207 Removing rear angle sensor for headlight beam adjustment...............................................................1207 Installing rear angle sensor for headlight beam adjustment.............................................................1207 94 94 19 Removing and installing drive motor for headlight beam adjustment.................................................1209 Removing drive motor for headlight beam adjustment.....................................................................1209 Installing drive motor for headlight beam adjustment...................................................................1209 94 98 19 Removing and installing control module for headlight beam adjustment..............................................1210 Removing control module for headlight beam adjustment..................................................................1210 Installing control module for headlight beam adjustment................................................................1210 96 INTERIOR LIGHTS, SWITCHES, THEFT PROTECTION................................................................................. 0 96 Additional alarm system M 536........................................................................................... 383 Removing alarm siren and tilt sensor................................................................................... 383 96 16 19 Removing and installing bulb for door warning light...............................................................1211 Removing bulb for door warning light...................................................................................1211 Installing bulb for door warning light.................................................................................1211 96 22 Bulb table and installation instructions............................................................................. 430 Bulb table............................................................................................................. 430 Installing bulbs....................................................................................................... 430 96 22 19 Removing and installing bulb for interior light...................................................................1212 Removing bulb for interior light.......................................................................................1212 Installing bulb for interior light.....................................................................................1212 96 41 19 Removing and installing bulb for luggage compartment light........................................................1213 Removing bulb for luggage compartment light............................................................................1213 Installing bulb for luggage compartment light..........................................................................1213 96 43 19 Removing and installing bulb for engine compartment light.........................................................1214 Removing bulb for engine compartment light.............................................................................1214 Installing bulb for engine compartment light...........................................................................1214 96 61 19 Removing and installing relay for main switch - GT2 - as of MY 2001...............................................2061 Installing the main battery relay......................................................................................2062 Installing inner EMERGENCY STOP switch.................................................................................2063 Removing the main battery relay........................................................................................2064 Removing the inner EMERGENCY STOP switch...............................................................................2065 Operating the main battery switch......................................................................................2066 Status - A - Road . Status - B - Racing track......................................................................2066 Actuating inner EMERGENCY STOP switch..............................................................................2067 Moving the EMERGENCY STOP switch to its starting position..........................................................2068 96 62 01 Radio remote control in hand-held transmitter does not function...................................................1215 Empty battery in hand-held transmitter.................................................................................1215 Radio transmitter outside lock-in range................................................................................1215 Atmospheric interference or interfering transmitters...................................................................1215 Energy-saving mode active..............................................................................................1216 Fault in hand-held transmitter or vehicle..............................................................................1216 96 62 37 Disassembling and assembling hand-held transmitter................................................................1217 Removing key from the bottom part......................................................................................1217 Installing key in the bottom part......................................................................................1217 96 62 55 Teaching hand-held transmitter....................................................................................1218 General................................................................................................................1218 Work preparation.......................................................................................................1218 Procedure..............................................................................................................1219 96 64 32 Converting installation position for tilt sensor, additional alarm system M536....................................1828 Tools..................................................................................................................1830 96 72 19 Removing and installing signal converter/immobilizer..............................................................1221 Removing signal converter/immobilizer..................................................................................1221 Installing signal converter/immobilizer................................................................................1222 96 85 19 Removing and installing passenger compartment monitoring sensor...................................................1223 Removing and installing passenger compartment monitoring sensor........................................................1223 Removing and installing passenger compartment monitoring sensor........................................................1223 96 87 19 Removing and installing control unit for alarm system.............................................................1831 Removing control unit for alarm system.................................................................................1831 Installing control unit for alarm system...............................................................................1833 Teaching control unit for the alarm system.............................................................................1834 97 WIRING...................................................................................................................... 0 97 Measurement of closed-circuit current................................................................................... 384 Tools.................................................................................................................. 384 Preparations on the vehicle............................................................................................ 384 Connecting measuring device........................................................................................ 384 Measurement............................................................................................................ 385 97 09 41 Repair of main wiring harness.....................................................................................1225 Removing main wiring harness...........................................................................................1225 Installing main wiring harness.........................................................................................1226 97 25 41 Repair of rear wiring harness.....................................................................................1228 Removing rear wiring harness...........................................................................................1228 Installing rear wiring harness.........................................................................................1229 97 68 Optical waveguide - MOST bus......................................................................................... 431 Specifications on handling the optical waveguide....................................................................... 431 Storage, packaging, transport...................................................................................... 431 Installing optical waveguides in the vehicle....................................................................... 431 Repairs............................................................................................................ 432 Plug connectors........................................................................................................ 432 Protective dust caps............................................................................................... 432 Control module plug connector (wiring harness side)................................................................ 433 Connectors......................................................................................................... 433 Removing and installing optical contacts............................................................................... 434 Removing optical contacts on plug side............................................................................. 435 Installing optical contacts on plug side........................................................................... 436 Removing optical contacts on bushing side.......................................................................... 437 Installing optical contacts on bushing side........................................................................ 437 Optical waveguide modules.............................................................................................. 438 Tools.................................................................................................................. 439 97 89 19 Removing and installing current distributor.......................................................................1836 Removing current distributor...........................................................................................1836 Installing the current distributor.....................................................................................1838 97 92 19 Removing and installing fusible element in the current distributor................................................1841 Removing fusible element from the current distributor..................................................................1841 Installing fusible element in the current distributor..................................................................1842 GROUP 9 WIRING DIAGRAMS............................................................................................................ 0 97 Wiring diagram for 911 Turbo (996), 01 model................................................................................1848 97 Wiring diagram for 911 Turbo (996), 02 model................................................................................1850 97 Circuit diagram for 911 Turbo (996), '03 model..............................................................................1852 97 Circuit diagram for 911 Turbo (996), '04 model..............................................................................1854 97 Circuit diagram for 911 Turbo (996), '05 model..............................................................................1856 996TT MASTER INDEX................................................................................................................. 0
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